TO AVOID MACHINED METAL CHIP ENTANGLING WORKPIECES

September 4, 2019

Working with metal part by turning or milling, the machined metal chip always entangling metal parts.

Normally, we can met following metal chip problems:

metal chip in machining process

1.Metal Chip winding, workpiece can not be loaded and unloaded

2.Metal Chips must be removed after the machining finished.

metal chip problem

3.Metal Chip winding and outlet blockage

4.Metal Chip winding, tools life short and damaged easily.

Do you have any chip trouble? If so, it means that you are not familiar with the workpiece machining. If this continues, someone else has processed 100 pieces, and you may only have processed 90!

What are the shapes of metal chips?

METAL CHIP TYPES

What can we read from cut metal chips?

metal chip shows machining problem

if the machined metal chip area broken, damaged. That means the cut tool was broken.
if the metal chip end has burr, it means the cutter tip damaged.
the metal chip color shows the cutting temperature in machining process.
if the metal chip has wavy cutting area, it means the cut tool was shacking in machining.

Cutting temp.（℃）	metal chip colors	Cutting Temp.（℃）	metal chip colors
200	Canary yellow	300	Cyan
229	Yellowish brown	320	Pale blue
240	brown	350	Blue-grey

Cut Metal Chip Principle and Direction

Principle	Method	Note
metal chip become thick	increase feeding	roughness become bad
metal chip become thick	cutter tip radius become small	roughness become bad damaged easily
metal chip become thick	Increasing Principal Deviation Angle	cutter tip strength become low
Metal Crimp Reduced radius	use suitable metal chip breaker	cutting resistance is higher, cutter shacking

WHAT ARE THE METHODS OF METAL CHIP BREAKING?

Increasing chip thickness after feeding is beneficial to chip breaking

increase feeding in machining process

deep cut machining

2.The radius of cutter tip roundness decreases and chip thickness increases.

cutter tip radius

metal chip types

3.Reduce the front corner

Chip compression ratio = hc/h

The bigger the compression ratio is, the easier chip breaking will occur. At the same time, the cutting resistance will also increase.
Compression ratio is related to linear velocity Vc. When Vc decreases, compression ratio increases, so reducing linear velocity is also beneficial to chip breaking.
The decrease of the front angle, the large chip deformation and the increase of the compression ratio are beneficial to chip breaking.

Use sharp edge cutting tool

As photo show, under the same feed conditions, the blade has sharp edges, which is conducive to metal chip breaking.

sharp edge cutting tool

Increasing the main deflection angle and thicker chips are beneficial to chip breaking

main deflection angle increase

main deflection angle increase machined metal chip

Protruding chip breaking groove to promote chip breaking

Scraping the surface of the chip from the protuberance of the chip breaking groove produces a dent—-Significant increase in chip thickness—Promoting chip breaking is highly damaging

chip breaking groove

The contact area with chips decreases and the chips discharge smoothly due to smooth contact with protrusions—Less damage to cutting tools

cut tool use in machining

Reduction of Chip Curling Radius

choose suitable cutter in machining process

cutter typs usage in machining

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