Types of Chips in Metal Cutting Process

Hello friends, In this article we will learn about types of chips in metal cutting process.


Chips are formed during machining process  like boring, turning, drilling, milling, shaping and much more.


These machining process done with the help of lathe machine, drilling machinemilling machine, shaper machine, etc.


So without wasting of time let's know types of chips in metal cutting as well as their advantages and disadvantages.


Types of Chips


There are following three types of chips are found in metal cutting process.

  • Continuous Chips 
  • Discontinuous Chips 
  • Continuous Chip with Built-up Edge 

Show in the figure different types of chips which are described below in detailed.

types of chips in metal cutting
Types of Chips in Metal Cutting 

Continuous Chips 

If the metal chips formed during machining process are without segments that means without any breakage, then it is called continuous type of chips.  


Continuous chips are formed when ductile metal is cut at high cutting speed and friction between the chips and the tool face is low.  


Factors which are responsible for the forming of continuous type chips

  1. A ductile metal such as mild steel is to be used.
  2. Large rake angle of the tool. 
  3. High cutting speed. 
  4. Minimal friction between the chip and tool interface.
  5. Small depth of cut.

Advantage and Disadvantage of Continuous Chips


There are following advantage and disadvantage during making of continuous chips


Advantages of Continuous Chips

  1. Surface finish better.
  2. Less heat generates.
  3. Long tool life.
  4. Less friction.
  5. Low power consumption.


Disadvantage of Continuous Chips

Due to continue form of chips without breaking then it is difficult to handle as well as dispose of for avoid this chip breakers are used. 

Discontinuous Chips 

If the chips formed during the metal cutting process are not continuous that means formed with breakage, then it is called discontinuous chips.  


Discontinuous chips are formed when brittle metal such as bronze, brass, cast iron are used.


Factors which are responsible for the forming of discontinuous type chips

  1. Low feed rate. 
  2. Small rack angle of equipment. 
  3. High cutting speed. 
  4. High friction force at the chip tool interface.
  5. Very deep cut.

Advantage and Disadvantage of discontinuous Chips


There are following advantage and disadvantage during making of discontinuous chips


Advantage of Discontinuous Chips

By using brittle metal, it gives a better surface finish as well as tool life increases and reduces power consumption.


Disadvantage of Discontinuous Chips

By using ductile metal, it gives a poor surface finish and also wears and tear increases.


Continuous Chip with Built-up Edge 

Continuous Chip with Built-up Edge is manufactured by machining on ductile material and with high friction between chip and tool interface.  


It is similar to continuous type chips but is less lubricated due to the built-up edge. 


Factors which are responsible for the forming of the continuous chip with built-up edge 

  1. High feed rate. 
  2. Small rake angle of the tool. 
  3. Low cutting speed. 
  4. Lack of coolant and this leads to increased friction between chip tool interfaces.


Advantage and Disadvantage of Continuous Chip with Built-up Edge 

There are following advantage and disadvantage during making of Continuous Chip with Built-up Edge


Advantage of Continuous Chips with BUE

It prevents damage to the cutting tool due to the built-up edge.


Disadvantage of Continuous Chips with BUE

Surface finish is rough due to the built-up edge.


I hope that I have clear all your doubts related to types of chips in metal cutting process


If you have still any doubt about regarding this topic, then you can ask me anything through comments or directly mail to me.


Thank You.

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