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Chip formation is a crucial part of CNC machining, with different types of chips forming depending on the material being cut. Discontinuous chips are more common in brittle materials and can cause poor surface finish. Manufacturers use lubrication, sharper tools, and chip breakers to prevent problems. Analysis of chip formation can be difficult due to various factors.
Chip formation typically occurs when a machine tool touches the edge of the material being cut. This is part of the computer numerical control (CNC) machining process, which usually occurs with milling, grinding, sanding and turning systems in manufacturing. In these techniques, chip formation usually occurs in a similar way. The movement of a tool typically creates a cutting plane, and depending on the type of material, the types of chips formed can be different. They can be discontinuous or continuous, while another variety is discontinuous chip with built-up edge; each type is carefully studied because it often affects the functioning of the machine and the quality of the final product.
The type of material being machined can make a difference in chip formation. Stronger materials generally don’t fracture as easily as weaker ones, so the chips can break off in a continuous band. With brittle substances, smaller chips typically form, causing more to break in a particular area.
In brittle materials, discontinuous chip formation is more common and can also occur when materials are cut at small angles or at low speeds. The surface finish of the material being cut is usually of poor quality, while a continuous chip is often considered to be the most efficient in machine cutting. A serrated chip is another type that often forms from metals with mixed cutting zones. Continuous chip with built-in edge formation occurs when metal chips can adhere to the cutting tool and even weld if there is enough heat. Very common with soft metals, this phenomenon can cause edges to loosen, possibly damaging the tool and workpiece.
When edges build up, manufacturers can add lubrication, install sharper tools, or use an ultrasonic vibration system to prevent problems from occurring. A chip breaker, which may be shaped like a groove behind the cutting edge, is sometimes used to prevent chips from sticking or tangling in the tool. Other shapes or devices can also address the problem of chip formation in machine tools.
Chip formation is often studied by manufacturers, especially in mechanical processes that require greater precision. Such an analysis can be difficult because CNC machining typically involves a high strain rate, while the part or tool material, temperature, and fluids used can all have an effect on the analysis and the phenomenon. The tool cutter can also make chip formation analysis difficult, compared to stamping processes where material formation occurs in a contained area.
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