This document discusses chip formation during metal cutting processes. It begins with an introduction to metal cutting and chip formation. It then describes the mechanics of chip formation, including how shear deformation causes material to be removed from the workpiece in the form of chips. It discusses factors that influence chip type, such as the material properties, cutting conditions, and tool properties. Finally, it describes the different types of chips that can be formed, including continuous chips, discontinuous chips, and continuous chips with built up edges.

1. CHIPS

2. CONTENTS
• Introduction
• Mechanism of chip formation
• Factors for chip types
• Types of chips
• Chip Breakers

3. INTRODUCTION
 Metal cutting or machining is the process of producing workpiece by
removing unwanted material from a block of metal, in the form of
chips.
 This process is most important because almost all products get their
final shape and size directly or indirectly by machining.
 Its major drawback is that in this process there is a lot of material lost
in the form of chips.

4. MECHANICS OF CHIP FORMATION
 A wedge shaped tool is made to move relative to theworkpiece.
 As the tool makes contact with the workpiece it exerts pressure on it
resulting in compression of the metal near the tool tip.
 This induces shear – type deformation within the metal and it starts
moving upward along the face of the tool.
 As the tool advances this process of shearing goes on increasing and
material is removed.

5. MECHANICS OF CHIP FORMATION

6. CHIP FORMATION IN DUCTILE MATERIALS
• As the tool makes contact with the workpiece it
Results in exerting pressure on the
material in front of it.

7. CHIP FORMATION IN BRITTLE MATERIALS
• CHIP FORMATION IN BRITTLE MATERIALS
Cracks develop in the workpiece near the tool tip.
• This crack results in stress concentration.
• Hence, crack propagation intensity increases and
• the chip detaches itself from the base material.
• This results in a discontinuous, irregular shape and sized chip.

8. FACTORS FOR CHIPTYPES
• Nature of work piece
• Nature of tool
• Dimension of tool
• Feed rate
• Cutting speed
• Cutting environment like temperature, friction, etc
• Friction between tool and work piece.

9. CHIPS TYPES
 Continuous chips
 Discontinuous chips
 Continuous chips with built up edges (BUE)

10. CONTINUOUSCHIPS
• If the metal chips are formed during machining is without
segments i.e. without breakage,than it is called as
continuous types of chips.
• Continuous chips are formed when the ductile
material ismachined with high cutting speed
and minimum friction between the chip and
tool face.

11. DISCONTINUOUS CHIPS
• If the chip is formed during machining is not continuous i.e. formed with
breakage is called discontinuous chips.
• Discontinuous types of chips are formed when hard and brittle
metals like brass, bronze and cast iron is machined.

12. CONTINUOUS CHIP WITH BUILT UP EDGE
 Continuous chips with built up edge is formed by machining ductile
material with high friction at the chip-tool interface.
 It is similar to the continuous types of chips but it is of less
smoothness due to the built up edge.