Types of Chips in Metal Cutting Process

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

 

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

 

These machining processes are done with the help of lathe machines, slotting machines, drilling machines, milling machines, shaper machines, etc.

So without wasting time let's know the 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 the 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 detail.

Types of Chips in Metal Cutting 

Continuous Chips 

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

 

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

 

Factors that are responsible for the forming of continuous type chips

1. A ductile metal such as mild steel is to be used.
2. The 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 the following advantages and disadvantages during the making of continuous chips:

Advantages of Continuous Chips

1. The surface finishes better.
2. Less heat generates.
3. Long tool life.
4. Less friction.
5. Low power consumption.

 

Disadvantage of Continuous Chips

Due to continuing form of chips without breaking then it is difficult to handle and also difficult to dispose of, chip breakers are used to avoid them.

Also Read: 

1. Chip Thickness Ratio
2. Types of Tool Wear

Discontinuous Chips 

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

 

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

 

Factors that 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 the following advantages and disadvantages during the making of discontinuous chips:

Advantage of Discontinuous Chips

Using brittle metal 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 that are responsible for the forming of the continuous chip with the built-up edge 

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

 

Advantage and Disadvantage of Continuous Chip with Built-up Edge 

There are the following advantages and disadvantages during the 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

The surface finish is rough due to the built-up edge.

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

 

If you have still any doubts about this topic, then you can ask me anything through comments or direct mail me. 

 

FAQ for Chips in Metal Cutting Process

Why discontinuous chips are formed?

Discontinuous chips are formed when brittle metals such as bronze, brass, cast iron are used as a workpiece in the machining process.

What causes the formation of continuous chips during the machining operations?

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

What is the difference between continuous and discontinuous chips?

If the metal chips formed during the machining process are without segments which means without any breakage, then it is called a continuous chip and If the chips formed during the metal cutting process are not continuous which means formed with breakage, then it is called discontinuous chips.

Which one of the following types of chips is found while turning cast iron?

Discontinuous chips will be formed because cast iron is a brittle metal.

What is the chip in metal cutting?

During the metal cutting or machining process, materials removed from a workpiece with the help of a cutting tool are known as chips.

What causes the formation of continuous chips with build-up edge during the machining operations?

Continuous chips with build-up edge are formed during metal cutting operation on ductile material when high friction is produced between chip and tool due to lack of lubrication.

 

Thank You.