Chip Formation in Conventional
Machining
By
Ameer Hamza Arif
Report submitted to the faculty of Engineering at PIEAS in partial
fulfillment of requirements for the Degree of BS Mechanical Engineering
Department of BSME
Pakistan Institute of Engineering & Applied Sciences,
Nilore, Islamabad, Pakistan.
June 3, 2020.
“Read in the name of thy Lord who created; [He] created the
human being from blood clot. Read in the name of thy Lord who
taught by the pen: [He] taught the human being what he did not
know.” (Surah Al-'Alaq:1-5)
“Then which of the blessings of your Lord will you both deny!”
(SURRAH RAHMAN)
ii
Dedication
First of all, this report is dedicated to the teachers of universe Prophet Muhammad
(S.A.W). This report is dedicated to my parents who helped me to achieve this
milestone. And after this I dedicate this to my teachers in the middle school who helped
me in every matter and made me think critically. I the end I want to mention that this
report is dedicated to my family and friends.
(Ameer Hamza Arif)
iii
Department of Mechanical Engineering,
Pakistan Institute of Engineering and Applied Sciences
(PIEAS)
Nilore. Islamabad 45650, Pakistan
Declaration of Originality
I pledge that the work contained in the report written by an author is completely genuine.
This report had not been written by anyone in the past. This report is only the hard work
of author and had not published in any of form.
I hereby also declare that I know and understand completely the terms “plagiarism and
copyright” so if any of the violation in rules of copyright found so I would be totally
responsible for that such consequences in future.
Signature: _______________________________
Name: __________________________________
Date: ____________________
Place: ____________________
iv
Acknowledgement
I thanks to all my friends who helped me to write this report and help me to
achieve this. But I want to mention Muhammad Fakhar and Mubashir who helped me in
every sort of matter to write this report. I also want to mention Muhammad Saad Rafiq
who helped me in this matter.
Here I also want special mention of Sir Ammar who is available every time to help
me. I am thankful to all of them who helped me. I am grateful to all of them for their
support and help without their help this would not be possible
(Ameer Hamza Arif)
v
2) Table of Contents
1) Introduction................................................................................................................1
1.1 Working Principle of Electrochemical machining Process.............................2
2) Materia and Methods................................................................................................3
2.1 Classification of Electrochemical machining (ECM) Process.........................3
2.1.1 Electrochemical Grinding Process.............................................................3
2.1.2 Electrochemical Turning Process...............................................................4
2.1.3 Electrochemical Milling Process................................................................5
2.1.4 Electrochemical Wire Cutting....................................................................5
2.1.5 Electrochemical Hole Drilling....................................................................6
2.2 Main Processing Parameters for Electrochemical Machining Process..........7
2.2.1 Electrolyte.....................................................................................................7
2.2.2 Flow Rate......................................................................................................7
2.2.3 Temperature Control..................................................................................8
2.2.4 Electrode Gap...............................................................................................8
2.2.5 Current and Voltage....................................................................................8
2.2.6 Material Removal Rate...............................................................................9
2.2.7 Tool Feed Rate.............................................................................................9
2.2.8 Tool Characteristics...................................................................................10
2.3 Design and Fabrication of Electro-Chemical Machine.................................10
2.3.1 Analysis on Tool Electrode Design...........................................................12
2.4 Electrochemical Based Hybrid Machining.....................................................13
2.5 Comparison between Electrochemical Machining Process (ECM) and
Micro machining Process (EMM)..............................................................................14
2.6 Advantages of Electrochemical Machining Process......................................15
2.6.1 Excellent Surface Finish:..........................................................................15
2.6.2 Dynamic three-dimensional Shapes:........................................................15
2.6.3 Material Removal Rate:............................................................................15
2.6.4 Irrespective of the hardness:.....................................................................16
2.7 Application Areas of Electrochemical Machining Process...........................16
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3) Results and Discussion............................................................................................18
3.1 Experimental Case Study.................................................................................18
3.1.1 Results of Experimental Study.................................................................19
3.2 Health and Environmental Safety Issues........................................................19
3.3 Electrochemical Machining and Future Concerns........................................20
3.3.1 Laser-Aided Jet Electrochemical Micromachining................................20
4) Conclusion................................................................................................................21
5) References.................................................................................................................23
6) Vita............................................................................................................................24
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List of Figures
Figure 1Electrochemical Machining Instruments..........................................................1
Figure 2 General Setup of Electrochemical Machining [3]...........................................3
Figure 3 Electrochemical Grinding Process....................................................................4
Figure 4Electrochemical Milling Setup...........................................................................5
Figure 5 Electrochemical wire cutting Setup..................................................................6
Figure 6 Electrochemical Hole Drilling Setup................................................................6
Figure 7Power Supply in Electrochemical Machining...................................................9
Figure 8Feed Rate w.r.t Distance in Electrochemical Machining...............................10
Figure 9 General Design of Electrochemical Machine [2]...........................................11
Figure 10 Process Flow Diagram of ECM [2]...............................................................12
Figure 11 Application Areas of Electrochemical Machining [2].................................17
Figure 12 Application Areas of Electro micro Machining...........................................18
Figure 13 Laser-assisted jet electrochemical machining process General View [2]. .21
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List of Tables
Table 1Comparison between Electrochemical Machining and Electro
Micromachining...............................................................................................................14
Table 2 Experimental Tool Material and Types [1].....................................................19
ix
Abstract
It is known from the theory of metal cutting that the study of machine chips provides the
cheapest and most effective way of understanding the mechanical properties of an object.
A review of the literature on the mechanics of TRICs reveals that relatively little attention
has been paid to these aspects during machine research. This overview has provided the
impetus to analyze the fundamental features of the machining of composites
experimentally and analytically incorporating the chip making mechanism.
This article discusses experimental work and finite element analysis to investigate the
mechanism of chip formation during machining of TRICs. This paper focuses on
understanding the influence of different shear parameters on the mechanism of
machining. During the orthogonal machining of TRICs, the chips generated by
experimental and finite element modeling were used for this purpose. Titanium alloys are
desirable materials for the aerospace industry because they are ideal
A combination of high specific strength, lightweight, anti-fracture properties and general
Resistant to corrosion. Therefore, chip morphology is very important in mechanization
studies
A study of cutting metals and tool wear. Chips are generally classified into four
Groups: continuous chips, built-up chips (BUE), non-stop chips and serrated chips.
Chip morphology and segmentation play an important role in determining mechanization
Equipment wear during machining operation. The dynamics of separated chip formation
Orthogonal shearing of titanium alloy Ti-6Al-4V is studied extensively with the help of
high speed
Imaging of the chip forming zone. Finite element model of chip formation of Ti-6Al-4V
Recommended as a non-stop type chip at constant cutting speed, but
Separate, chip at high cutting speed. Prediction by using finite-element modeling method
And helps reduce the simulation process in the machine when creating chips
Cost of production based on saving of cut tool life and machining time.
x
1) Introduction
The dynamics of orthogonal metal shear has been investigated by many authors,
particularly in this field Of the high-speed machine (H.S.M.). Among other things, the
benefits expected from H.S.M. Increase Capacity for machining many advanced
materials such as productivity, titanium or hardened alloy steels. Other desirable effects
are chip section. Excellent condition of the surface and the adiabatic event Based on the
shear band, which aims to reduce shear forces. Numerous studies have been published
about the analytical model of orthogonality Cutting [I - 61, high-speed shear number
simulation [7], study of adiabatic shear banding [8], or the dynamics of the chip section
[9 - 131. To obtain results at a wide range of speeds, a new test system has been designed
[14], its The principle is based on the Hopkinson pipeline technique. This device allows
true orthogonal cutting Semi-stationary conditions with speeds of up to 100 mph. The
purpose of this paper is to present the first results obtained through this study. The tests
are run on medium steel (medium carbon steel) with a speed of 7 m / s 100 m / s and for
different rack angles (-5, 0, 5 degrees). The shear forces were measured and the chips
Were collected and analyzed from a morphological point of view. The results show the
main The influence of the shear speed and the rack angle of the process, especially at the
end In a cutting band or chip section. Communication is one of the key aspects that is put
into evidence Between the position of the chip section and the shear forces.
1.1 Working Principle of Electrochemical machining Process
The The form of the chip is one of the main parameters affecting the productivity in the
metal cutting industry. In general, there are two groups of chip forms, (1) acceptable
chips and (2) unacceptable chips, for ease of maintenance. Acceptable chips do not
interfere with work or machine tools and cause no problems of disposal. Unacceptable
chips can interfere with regular manufacturing operations, as they can pose a safety
hazard to tool and workpiece operators. Chipping can damage the surface finish and lead
to unexpected unexpected tool failure.
4.1 Chip formation (experimental)
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Normal chips were formed from most experimental runs during machining (turning) of
6061 aluminum 15 vol. % SiC (p) alloys in dry cutting under different cutting conditions
as shown in Figure 3. Depending on the cutting conditions, the chips produced are either
Continuous Saw Tooth or Semi Continuous Saw Tooth.
An expanded cross-section of the chip shows the profile of the tooth that is prominent on
the outer surface of the chip Figure 4. The rest of the chip looks plain without big cracks.
During deformation, the gross fracture begins on the free surface of the chip and
propagates toward the tool nozzle with the thickness of the chip. The gross fracture
usually ends half way and the rest of the chip is removed by a flow-type deformation.
The actual pattern of disability development can be seen from the SEM photograph of the
chip root Figure-5.[CITATION Ano09 \l 1033 ]
The effect of cutting speed is equal to the effect of strain rate and temperature on
deformation. At low cutting speeds, the strain rate is low and low temperature
deformation occurs. However, at higher cutting speeds the strain rate is higher and the
temperature deformation occurs. Therefore, during machining at low shear speeds, the
material behaves fragilely with little effect of temperature or strain rate. At low cutting
speeds, the displacement of the reinforcing particles is low, producing voids by
displacement or breakage of the reinforcing particles. Therefore, fragile failure becomes
even more prominent. This causes the tooth profile to appear on the chip. The effect is
more pronounced if the cutting speed increases.
2) Material and Methods
The part of the object that has been sacked
The object of the cutting tool is called the chip. Chip creation is a complex
Occurrence when a force is applied to the cutting tool. Meaning
The cutting edge deforms due to the cutting process.
You can see the chip formation and its movement with the tool face
From an ideal model where the stack of oblique game cards is pushed
xii
Against the instrument. In general, chip creation is very much in the process of
machining
Important for the manufacturer. The shape and size of the chip obtained from A
The machining process refers to the type and quality of the material regardless
Machining process. Characterization of chip formation in hard machining
Totally different from the usual machining. In the Dactyl Machine
For materials, chip formation is very heavy plastic
Deformation in the shear zone. The creation of saw-tooth chips is one
Primary properties in the machining of geometrically hardened steels
Limited cutting tools. Catastrophic failure within the primary shear zone
Rotational cracks usually occur during saw-tooth chip formation
To initiate or propagate or to cause thermo-plastic instability
(Barry & Byrne 2002; Davis et al. 1997).
Periodicity theory first considers the time-slice crack
Go downward with the cut, forming near the surface of the work
Plane towards the tool tip. According to Davis et al. (1996) Chip morphology
This is independent of the working material microstructure, but it is the function of the
tool
Wear when finished with hardened steel. Elbestvai et al. (1996)
Developed a chip-making model in which chip creation begins
Consider starting a crack on the free surface of the work piece
The direction of crack initiation using the surface layer energy criterion.
102
Generally the problem with chip creation is very important
Manufacturers. This is not linked to the associated problem
Classification of chips and, most importantly, the theory behind chips
Formation. This investigation appears to be about the creation of separation
Chips during the hard turn of AISIM2Steel. Only chips though
By-products of machining operations, they are very important
xiii
Mechanism and Surface Study of Metals
Hardness, shear force and tool wear.[CITATION Bha05 \l 1033 ]
2.1 Types of Chip Formation
The phenomenon of chip segmentation phengenon has been extensively investigated and
studied worldwide.
Attempts to explain the chip morphology in cutting the titanium alloys back to work
was created by Cook in 1953 [10]. Investigated the chip morphology of titanium alloys at
Different cutting speed and suggest a thermodynamic view of chip formation. Nakayama
et al.
[11], Shaw and Vyas [12] proposed a false-positive theory for the formation of a solid
metal cracking.
Komanduri et al. [13] studied the chip formation process during Ti-6Al-4V cutting and
we proposed a concept known as a 'disaster shear chip'. Another first chip search
Partitioning of synthetic fragments of titanium alloys was performed by Lee [14], Gente
no
Hoffmeister [15]. Prediction using finite-element model for chip morphology and
characterization
during machinery of titanium alloys taken by J. Hua and R. Shivpuri [5]. On time
The manufacturing process, the chip production can be divided into four types:
A continuous chip. This type is usually formed during the manufacture of complex
machinery. It's old here
high cutting speed and / or large rakes. The conversion of chips occurs once with a small
sword
four and the main shear zone, resulting in friction. The chips improve the second shear
zone at the interface-chip interface. The second level gets deeper as the rise of tool-chip
battles deepens.
Though they usually produce a good end to the world, but continuous chip construction
should be
avoided because it interferes with the mechanical process. This problem can be overcome
by the use of
A chip-breaker is a tool that is attached to the top of the tool that prompts the chip to
move higher
xiv
firmly, hitting the work piece and breaking [16].
In progress with Buge-up Edge. The built-in edge (Bue) is basically the same as
continuous chips.
However, during the formation of the front chip, when the metal flows through the chip-
tool zone, small particles
the metal begins to attach or burn itself to the cutting edge of the cutting tool. There are
many
BUE composition conditions:
• Flammable metals must be mixed
• Binding steel.
• High temperature.
• Elevators and high pressure.
• Velocity should be low.
• Lower the cutting depth.
• Increase angle angle.
• Using a sharp cutting tool.
• An effective cutting tool is used.
Advisory chip.This type usually occurs during the operation of the measuring equipment
such as glass and silicon. This type of chip also happens when machinery is made using
cutting tools too
small angles
grease or cutting liquid. Negative chip design features are:
• Maximum cutting depth.
• Angles are lower rakes.
• Lack of effective cutting fluid.
• The lower wood of the machine tool
32 Production Engineering and Processes
The manufacture of chip manufactured There are manufactured during mechanical
equipment semi-continuous with
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areas of high-quality low-grade metal. It usually happens in metals when energy is
reduced
very hot. An example would be Titanium alloy [16].
2.2 Need for Chip formation
The aim of this study is to get a better understanding of Chip formation when AISI M2
steel is machined. That, in the long run, is In industry, knowledge may be used to achieve
a more robust machining process. Quick machining tests are conducted to examine the
shape of the chips. While chips are a by-product of machining operations, they are very
effective Important to study the process of machining as they can facilitate in
Understanding processes of deformation occurring at microscopic level For the duration
of cutting metal. Therefore, colour, scale, in this investigation It analyzed the shape, chip
length, chip thickness and chip width of the chips.[CITATION Hew05 \l 1033 ]
2.3 PERFORMANCE CHARACTERISTICS OF CHIP
SIZES
2.3.1 The Influence of Process Parameters on Chip sizes
As hard turning is a process of machining its involves cubic boron
Inserts nitrate (CBN) tool for machining work piece materials. An element
Link between the device and interactions of the workpiece when hard turning
Get the simple consideration on producing chips better. And it's just easy
Geometric connection between cutting speed, feed, cutting depth on chip
It analyzed weight, chip thickness and chip width. Observing the
103 I don't think so.
Chip shape, while the process of hard turning is essential for the definite classification
Quality smashing through various machining peripheries. The vision as
Both the cutting surface and the soil are both critical for thoughtful generation
Reliable.
2.3.2 Chip Length Measurement
Saw-toothed chips have a characteristic maximum and a minimum
length. The method for measuring these two from the microstructure is
described in, where the lines representing maximum and minimum chip
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length are perpendicular to the rake surface. An average chip length was also
calculated from these values according to
Average Chip Length =
Maximum chip Length +Minimum chip Length
2.4 CHIP MORPHOLOGY
Chip morphology is an important aspect that is commonly used to
evaluate the machinability of AISI M2 steel. Qualities of chip morphology
can also give valuable information for tool design. By study of chip
morphology, investigators have given various important theories like
thermodynamic theory of chip formation, stages of saw tooth formation etc.
The relative study of chips obtained for the various cutting speeds can help
the researchers to identify some of the properties that favour the instantaneous
shearing. The mechanism of chip formation at a high speed is different from
that obtained in conventional machining.[CITATION Hoc03 \l 1033 ]
2.5 Chip Formation Mechanism
It is important to study the formation of chips during the
machining process as the former affects the surface finish, cutting forces,
temperature, tool wear and dimensional tolerance. Understanding the chip
123
formation during the machining process for the specific materials will allow
determining the machining speeds, feed rates and depth of cuts for efficient
machining and increased tool life in the specific actual machining operation.
The chips can be divided in three groups according to their characteristics and
appearance continuous chip, discontinuous chip and segmented (saw
tooth)serrated chip.
2.5.1 Continuous chip formation
At a cutting speed of 125 m/min the surface finish of the work
xvii
piece was the rich due to forming continuous chips .Various harshly stressed
material was obvious on the sliding surface of chips was the case with the
turning surface of the work piece. The greatly deformed materials point out
extreme or reliable. BUE that occasionally shaped on the cutting edge
effecting in surface finish of the work piece material. Refusal slide areas were
obvious on the chip underside, perhaps indicating the prevalence of fit at the
tool-chip interface.
2.5.2 Discontinuous chip formation
The discontinuous chip is usually formed when cutting hard
materials, partly because these materials cannot withstand high shear forces
and therefore the chips formed shear cleanly away. However, the chips
formed may be firmly or loosely attached to each other or may leave the
cutting area in a fine shower. When discontinuous chips are formed there is a
greater possibility of tool chatter (unless the tool, tool-holder and workpiece
are held very rigidly) due to pressure at the tool tip increasing during chip
formation and then releasing suddenly as the chip shears.
At a cutting speed of 65 m/min for more the streaks along the
length of the chip underside were smooth. The extent of discontinuities on the
chip underside decreased as the cutting speed. Streaks and microspores were
more evident as the cutting speed decreased as a result of softening and
probably partial melting due to sliding of the chip against the rake face of the
cutting tool. No stick areas were evident on the chip underside indicating
probably the predominance of sliding at the tool-chip interface.[CITATION Raj93 \l
1033 ]
2.5.3 Segmented (Saw tooth) chip formation
Segmented chips are semicontinuouschips, with a saw-tooth
appearance. Sometimes these chips are referred as cyclical, as they alternate
high shear strain zones with low shear strain zones. Usually this type of chip
is associated with difficult-to-machine harden metals at high cutting speeds.
xviii
They are produced very similarly to the discontinuous chips and the process
can be explained by the stick-slip model, based on the friction between the
chip being formed and the cutting tool.[ CITATION Raj99 \l 1033 ]
Segmented chip formation is the discontinuous formation of a chip
with still more or less connected elements, yet with significant variations in
the degree of deformation along the flow path. Saw tooth chip formation is
related to the localisation of plastic flow by shear, which occurs periodically
along the length of the chips. It primarily occurs with negative rake angles,
moderate cutting speed, higher feed rate, high depth of cut and a higher chip
thickness.
3.1 Analysis of chip produced at optimized value of
machining parameters
The chips produced at the optimized values for hard turning of
AISI M2 steel chips was analyzed by using scanning electron microscope.
The sharper edges of the chips produced in hard turning machining, when
turned at optimized values were significantly reduced. The continuous and
curling chips produced in dry machining gets curled within the tool and work
interface and needs to be removed at short interval during hard turning. The
work piece and tool inserts interface tends to be less affected by the chips
produced in hard turning machining as they get break off at regular interval
and forms a discontinuous chips. The colour of the chips turns (darkblue)
,while turned at hard turning environment.[CITATION Ram12 \l 1033 ]
Segmental chips (serrated) also called saw-tooth chips are mostly
formed during machining of hardened steel under hard cutting conditions for
hard turning of AISI M2 Steel (60HRC) using CBN tool inserts. For cutting
speed of 95 m/min with feed of 0.15 mm/rev and with depth of cut
0.45mm.Moderate cutting speed, high feed rate ,high depth of cut(V2,f3,d3 )
at cutting condition saw tooth ship were produced . The chips obtained have
xix
been saw tooth chip and is shown in Figure 5.1. Experimental sample 14
Figure 5.1(n) high cutting speed, low feed rate and high depth of cut
(V3,f1,d3) cutting condition with chip thickness 0.15623 mm and chip width
128.[CITATION Wil71 \l 1033 ]
0.5599 mm, grey colour spiral shape long continuous chips were obtained..
At this cutting combination good surface finish was obtained and performance
characteristics of material improved.
RESULTS AND DISCUSSION
5.7.1 Effect of Cutting Parameters
It is always chosen to have discontinuous chips for all cutting
parameters. For cutting speed of 65 m/min with feed of 0.15 mm/rev and
with depth of cut 0.15mm. The chips obtained have been discontinued and is
shown in Figure 5.12. If the cutting speed is increased to 95 m/min, feed 0.15
and depth of cut 0.15mm, the chip obtained have been spiral in shape and is
shown in Figure5. 17, whereas if the cutting speed is increased to 125m/min
0.15mm/rev feed rate and 0.45mm depth of cut, the shape of the chip
obtained was continuous ships.
Chips are shaped, because of cutting among work piece material
and cutting tool edge. For the duration of hard turning equally continuous and
discontinuous chips have been shaped. For all the tests conducted, the shapes
of the chips shaped have been classified in to three types namely spiral, curl
and spring. The image of the chips shaped for different cutting conditions
considered are shown in Figure 5.1(a)-5.1(t). The SEM image illustrates saw
tooth-like chips of various shapes. Chip configuration with saw tooth is too
confirmation. This is because of repeated fractures that start at the exterior of
the tasks and carry on down beside a shear plane towards the tool angle and
shear flow region is emerged for preferred cutting conditions. The chips
shaped, when machining of hardened steel.
xx
129
5.7.1.1 Influence of the Cutting speed on the form of chip
With increase of the cutting speed, the cutting bands become more
and more intense with a considerable reduction in the width of contact
between the segments up to fragment . This is attributed to the phenomenon
of localized deformation in the primary cutting region that becomes more
important with the increase in the temperature. The mechanical properties of
material thus decrease in the cutting region by reducing resistance to the
plastic deformation and thus cause an abrupt shearing of the chip by creating
a plastic instability. It should be noted that for a feed rate of 0.10mm/rev, the
appearance frequency of the chip is more often as the cutting speed (V) is
higher. In fact, this morphology is often observed in the case of the machining
of harden steels and of low thermal conductivity. The low thermal
conductivity and the rapid dissipation of energy lead to consider the cutting
region as an area of adiabatic shear. These chips were formed by a
localization of deformation and catastrophic cutting angles to the increase in
hardness and brittleness of material. Thus the mechanism of production of
chip is based on the initiation of a crack followed by a slip.
5.7.1.2 Influence of the Feed on the Form of Chip (Saw tooth)
The analysis of the chips shows that the feed rate by hard turning
influences considerably the morphology of the chips. Certainly, the hard
turning of AISI M2 steel hardened (60 HRC) with small feed rates (f = 0. 05
mm/rev) allows obtaining a discontinuous chip, this chip is due to a quasistationary
plastic deformations in the zones of shearing .It should be noted
that, with the increase in the feed rate and at moderate cutting speed of (V) =
95 m/min, the chip thickness is increasingly scalloped. It means that it takes
more and more the shape of the saw-tooth chip due to cyclic cracking by
creating very intensive shear bands.
xxi
130
5.7.1.3 Effect of Chip thickness
From Figure 5.1, it was found that the chip thickness tends to
decrease as the cutting speed decreases for all of the parameter investigated.
However, the value of average chip thickness also decreases as the feed
decreases. Hence, the feed rate influences the thickness of the chip as the
cutting speed does. This is due to the increase in the unreformed chip
thickness with increasing feed and the tangential force is proportional to the
undeformed chipthickness as this increase will result in an increase in shear
plane area. Similar to when the cutting force decreases, the deformed chip
thickness also decrease. This happened when the force Fc acts downward on
the tool tip and tends to deflect the tool downward. This force is that which
supplies the energy required for the cutting operation. It is assumed that as the
chip thickness decreases so also does the power consumption of the machine,
owing to low chip thickness during chip removal. At this same time less
vibration was observed and surface roughness improves and tool wear
reduced
5.7.1.4 Effect of Cutting Forces and Temperature on Chip Formation
The cutting force as well as one of the dominant parameters
affecting the chip morphology .The cutting tool CBN inserts and work
piece interface experiences many cutting forces and thrust force when hard
turning. The cutting force is affected by the rake angle and tool cutting edge
radius. Cutting force increases with increased in feed and depth of cut and
increase in cutting edge radius . An increased cutting force produces chip
thick and the segmented chips are formed as a result of cutting force
variations.
131
High temperature at the cutting zone is a main problem in
xxii
machining and involves the chips produced. A reduction in temperature at
the cutting region, improves the productivity of the process and chips size
variation is minimized owing to lower friction at the tool work piece
interface. Strong cutting deformation guides to an increase in temperature
opposite the tool tip which weakens the material by thermal softening.
The deformation therefore focused in this region and causes the formation
of thin, heavily deformed shear bands. The cutting speed must be low
sufficient to ensure that heat conduction out of the shear zone is limited or
negligible.
5.8 SUMMARY
In this chapter, exclusive points such as, causes of chip, formation
of chip, classification of chip, measuring of chiplength,chipthickness and chip
width, chip morphology and chip formation mechanism have been discussed.
The optical picture of the material and characteristics of the chip used in this
research work has been highlighted. The detailed explanation of the measured
chip and equipments used to chip measurement in this research work for the
machinability assessment of AISI M2 steel are discussed. The analysis of
variance (ANOVA) has been used to investigate the design parameter
significantly affecting the responses of the machining processes. It is clear
from the ANOVA tables that cutting speed and feed rate are the dominant
players in analysis of chip length, chip thickness and chip width while
machining of AISI M2 steel. The various mathematical modelling,
optimization and selection techniques have been discussed in the forth coming
chapter.
xxiii
4) Conclusion
In conclusion, the formation of the chips depends on the cutting speed, feed rate, and so
on Cutting fluid. Prediction of primary shear zone using finite element modeling method
And helps reduce the simulation process in the machine when creating chips
Cost of production based on saving of cut tool life and machining time. The future
Research should focus more on initiating and spreading cracks within the primary cut
Zone of work-piece object.
xxiv
5) References
[1] A. N. B.Dahotre, "Journal of the European machining Society," vol. volume 29, no.
issues 6, pp. Pages 969-993, 2009.
[2] B. Bhattacharyya, M. Malapati and J. and Munda, "Experimental study on chip
fromation,," in Journal of Materials Processing Technology, 2005, pp. 169(3), 485-
492.
[3] M. S. Hewidy, "Controlling of metal removal and chip thickness," Journal of
Materials Processing Technology, vol. 1, p. 348–353, 2005.
[4] H. Hocheng, Y. Sun, S. Lin and a. Kao, "A material removal analysis and chip
study," in Journal of Materials Processing Technology, 2003, pp. 264-268.
[5] K. P. W. B. S. C. L. Rajurkar, Monitoring and Control of chip thickness, pp. 115-217,
(1993).
[6] K. Rajurkar, D. Zhu, J. McGeough, J. Kozak and A. and DeSilva, New developments
in machining, vol. 1, pp. 567-579, 1999.
[7] M. S. D. S. Ramandeep Singh, Study of Machining Process For Drilling Hole, vol.
Vol. 1, no. Issue 10, December- 2012.
[8] J. F. Wilson, Practice and Theory of Machining, New York: Wiley, 1971.
xxv
6) Vita
The author of this report is born in the city of saints, Multan. The author has done matric
from OXFORD high school Multan and got full scholarship in FSc. Pre-Engineering
from KIPS college Multan. After this he worked hard and declared as one of topped
students in the Multan board. He not only secured position but also, he became able to
secure admission in the Prestigious university of Pakistan, PIEAS which is also the
number 1 university in Pakistan. Now he is currently doing Mechanical Engineering from
there and has written this report to be well aware of manufacturing technique
“Electrochemical Machining Process”.
xxvi
