LAB. No.

2 Metal cutting theory

Tool Geometry and chip formation

Introduction
The chip formation process implies that a fresh metal interface is continually
produced between the tool material and the workpiece at varying cutting forces,
angles and temperatures. When a cutting edge performs its metal cutting
function properly, it deforms some of the workpiece material plastically and then
pushes it off.
Cutting tools used to remove the chip from the workpiece have a specific
geometry in order to cut efficiently.
The chip is enormously variable in shape and size in industrial machining
operations; Figure 1 shows some of the chip forms. The formation of all types
of chips involves a shearing of the work material in the region of a plane
extending from the tool edge to the position where the upper surface of the chip
leaves the work surface. A very large amount of strain takes place in this region
in a very short interval of time, and not all metals and alloys can withstand this
strain without fracture. Gray cast iron chips, for example, are always
fragmented, and the chips of more ductile materials may be produced as
segments, particularly at very low cutting speed. This discontinuous chip is one
of the principal classes of chip form, and has the practical advantage that it is
easily cleared from the cutting area. Under a majority of cutting conditions,
however, ductile metals and alloys do not fracture on the shear plane and a
continuous chip is produced. Continuous chips may adopt many shapes-
straight, tangled or with different types of helix.

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LAB. No. 2 Metal cutting theory
Tool Geometry and chip formation

Fig. 1 Chip shapes

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 LAB. No. 2 Metal cutting theory
Tool Geometry and chip formation

:Lab Objective

● The main purposes of this laboratory are:

- To identify and measure the cutting angles of right-hand single point tool
according to the ORS system.
- To study the effect of changing cutting conditions (feed, speed and depth of
cut) on chip’s shape.

:Equipment, tools, and materials required

- Center lathe machine
- Cutting tool (right hand single point cutting tool)
- Workpiece (low carbon steel)

:Requirements
:This report should be contains the following items

A neat sketch of the cutting tool showing its different elements, and the (1)
.measured angles according to ORS system
.The different shapes of chips under different cutting conditions (2)
.Answers for the questions at the end of this report (3)

:Lab procedure

.Examine a right-hand-cut tool and identify its elements and angles (1)
carry out a longitudinal turning operations for a workpiece specimen made (2)
from low carbon steel with HSS cutting tools under different cutting conditions
.(change one factor at a time and keep all other unchanged)

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 LAB. No. 2 Metal cutting theory
Tool Geometry and chip formation

:Results
:Tool geometry .1

Draw here a neat sketch of the right hand cutting tool showing its elements and
:angles

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 LAB. No. 2 Metal cutting theory
Tool Geometry and chip formation

Effects of cutting conditions on chip’s shape .2

Process Cutting conditions

.No V S a Chip’s shape Chip’s sketch
.1

.2

.3

.4

.5

.6

.7

.8

.9

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 LAB. No. 2 Metal cutting theory
Tool Geometry and chip formation

:Review Questions .3

.Explain how workpiece metal is transformed into chip (1)

(2) List the different types of chips

(3) From the test results, determine the effect of feed, speed, and depth of
cut on chip’s shape