Papers by Keyword: Chip Breaker

Abstract: The handling of continuous chips in bulk can present a major problem in metal cutting. The controlling and breaking of chips is accomplished by a chip breaker. A reliable and practical chip controlling mathematical model was established after Chip breaking requirements and chip breaking grooves parameters being analyzed in this paper. The results can be important to practical on a variety of chip breakers and chip-breaking grooves parameters desig

Abstract: This paper presents a methodology to design and manufacture a chip breaker in a PCD turning tool. The objective is to avoid the surface roughness and chip evacuation problems produced by long chips in turning processes. An analysis of the process is made to design a suitable chip breaker shape for semi-roughing and finishing operations in aluminum turning. FEM simulation and experimental test are used to understand the chip formation and breakage processes leading to improved chip breaker geometry. The new designed geometries are micromachined with laser in the PCD tools, and the improvement in the chip control is proved experimentally.

Abstract: This study has focused on the chip-breaker design and experimental cutting of Inconel 718with the designed chip breaker. The process of chip breakage for Inconel 718 with respect to cutting speed, depth of cut and feed rate then chips and machined surfaces were analyzed from the experimental results. For this purpose, the nickel-base super alloy, Inconel 718was machined with a two layers PVD coated (TiAlN-TiN) carbide insert at feed rates of 0.10, 0.15, 0.20, 0.30 mm/rev, 0.5, 1, 1.5, 2 mm with depth of cuts, and 30, 45, 60, 75m/min cutting speeds using developed dynamic chip breaker with Negative tool holders in dry cutting conditions. Chip pictures and surface roughness (Ra) were recorded. Chip breakability during machining of the Inconel 718 depends on DC motor speed and chip breaker position on the cutting tool. The experimental results show that the designed chip breaker can break long chips at any cutting condition and acceptable surface finish can be achieved. In addition to this, according to cutting conditions, the usage of dynamic chip breaker on the surface of cutting insert is measured between 1% and 40% cooling effects using negative tool holder.

Abstract: The objective of this paper is experimentally investigation of the effects of different chip breaker forms on the cutting forces according to various cutting parameters. AISI 1050 workpiece material, most used material in the manufacturing industry, and SNMG 120408R inserts and PSBNR 2525M12 tool holder have 75° approaching angle according to ISO 3685 are used in the experiments. Seven groups chip breaker form were used in the tests. The chip breaker forms are the coated inserts MA, SA, MS, GH and standard, and the uncoated inserts MS and standard. These inserts are Mitsubishi UC 6010 and UTI20T grade; correspond to ISO P30 and P15 grade, respectively. Machining tests were carried out by using five levels of cutting speeds (150, 200, 250, 300, 350 m/min), three levels of feed rate (0.15, 0.25, 0.35 mm/rev) and two levels of depth of cut (1.6, 2.5 mm). Cutting forces were measured using Kistler dynamometer. The test results show that the highest cutting force values were measured on SA, GH, MA forms, respectively. Complex chip breaker forms cause the increase of the cutting forces. Although the cutting forces on the uncoated inserts were partly small in light cutting conditions, it has increased on the uncoated inserts in heavy cutting conditions compared to coated inserts.