CHIP FORMATION MODEL

Material Removal Processes

Machining process chip formation

Microscopic View

Shearin
g
process

Microscopic View

Schematic illustration of
a two-dimensional
orthogonal cutting

Microscopic View
Assume a shear
plane instead of
a shear zone
t0

tc

Machining
Cutting action involves shear
deformation of work material to form
a chip
As chip is removed, new surface is
exposed

Orthogonal cutting

Machining
Simplified 2-D model of machining
that describes the mechanics of
machining fairly accurately

Orthogonal cutting: as a threedimensional process.

Machining
Cutting action involves shear
deformation of work material to form
a chip
As chip is removed, new surface is
exposed

(a) A cross-sectional view of the

machining process.
Original surface = uncut surface
New surface = finish surface

(b) tool with negative rake

angle; compare with
positive rake angle in (a).

tr
o
c

Chip Thickness Ratio

where
r = chip thickness ratio;
to = thickness of the chip prior to chip
formation (depth of cut); and
tc = chip thickness after separation

Chip thickness after cut always

greater than before, so chip
ratio always less than 1.0

rta
c
o
s

n
1in

Determining Shear Plane

Angle

Based on the geometric parameters

of the orthogonal model, the shear
plane angle can be determined as:
where r = chip ratio, and = rake angle

Chip Formation

More realistic view of chip formation, showing shear zone rather

than shear plane. Also shown is the secondary shear zone resulting
from toolchip friction.

Shear Strain in Chip

Formation
Shear deformation can be idealized
(approximated) by a series of parallel
plates sliding against one another to
form the chip.
Simulation
ChipFormation2.swf
shear plane angle

Shear Strain in Chip Formation

Shear strain during chip formation: (a) chip formation depicted

as a series of parallel plates sliding relative to each other, (b)
one of the plates isolated to show shear strain, and (c) shear
strain triangle used to derive strain equation.

Shear Strain
Shear strain in machining can be
computed from the following
equation, based on the preceding
parallel plate model:
= tan( - ) + cot

Where = shear strain, = shear

plane angle, and = rake angle of
cutting tool

v
v
v
c
s

cos
sin
co
s
Velocity Diagram
vc

At cutting zone

vs

v is the cutting velocity

(speed)
vs is the velocity at which
shearing takes place in
shear plane (shear velocity)
vc is the velocity at which
the chip compressed (chip
velocity)

vc 90-+

vs

90-

Chip Formation
Chip formation
mechanism
Material properties
Cutting tool geometry
Machining parameters

Primary shear
zone

secondary shear
zone

tool

secondary
shear zone at
the tool-chip
interface