ME 4700/ ME5701

Manufacturing Processes
INSTRUCTOR: NA TYRER
CHIP FORMATION

• Metal chips in machining are produced by a shearing

( plastic deformation) mechanism
• Shearing takes place along an angle of 𝜑 with the workpiece
surface

MANUFACTURING PROCESSES
• Below the shear plane, the elastic deformation of work
piece
• Above shear plane, chip formation

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MAJOR INDEPENDENT VARIABLES
• The type of cutting tool and its properties
• The shape of the tool, its surface finish and
sharpness
• Workpiece material, its properties, the machining
temperature
• Cutting conditions - such as speed, feed, depth of cut
• Type of cutting fluid

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CLASSICAL LITERATU
• Characteristics of the machine tool, especially the
stiffness
• Tool holder & work holding devices 3
MAJOR DEPENDENT VARIABLES
• The type of chip produced
• Force and energy dissipated
• Temperature rise in the workpiece, the chip and
cutting tool
• Wear, chipping and failure of the tool
• Surface finish and integrity of the workpiece
after it’s machined

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CLASSICAL LITERATU
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TWO DIMENSIONAL CUTTING PROCESS

MANUFACTURING PROCESSES
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TEMPERATURE OF CUTTING
TOOL
1. Heat generated due to sliding of chip along faces
of tool.
A see max temperature rise due to frictional heating.
B plastic deformation produces heat, greatest temp
rise due to plastic deformation will be B.

MANUFACTURING PROCESSES
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• Combined effects of friction and plastic formation
procedure highest temperature rise at point C which
approximately mid-way between A and B

MANUFACTURING PROCESSES
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MANUFACTURING PROCESSES
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CLASSICAL LITERATU
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TYPE OF CHIPS
• 1. Continuous chips – common with high cutting speeds
and large rake angles. Chips can get tangled in the
machine tool.
• Can be prevented by using a chip breaker.
• 2. Discontinuous chips – brittle materials display this
type of chips.
• can produce non-uniform cutting forces that produce

MANUFACTURING PROCESSES
machine tool vibration – high waviness and
dimensional problems in the workpiece.
• 3. Build-up Edge chip (BUE)
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CLASSICAL LITERATU
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CLASSICAL LITERATU
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CHIP BREAKER
As a result of strain hardening,
a chip generally becomes
harder, stronger and less
ductile than the original
workpiece. As the rake angle
decrease, shear strain increase.

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CLASSICAL LITERATU
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