1. Manufacturing Processes
Metal Cutting
Manufacturing Processes

2. Outline Metal Cutting Chip Formation Processes Chip Formation Effects
Control
Conditions
Back rake angle
Shear angle
Chip Formation
Continuous formation
Built up edge formation
Discontinuous formation
Effects
Chip formation

3. Chip Formation Processes
Shaping
Turning
Milling
Drilling
Sawing
Broaching
Grinding

4. Machining Operations

5. Machining Operations

6. Machining Operations - Sawing

7. Machining Operations - Grinding

8. Basic Cutting – Face Cutting

9. Basic Cutting – Pocket Cutting

10. Basic Cutting – Turning Diameters

11. Basic Cutting – Thread Cutting

12. Basic Cutting – Surface Grinding

13. Chip Formation Processes
Control
Feed
Speed
Depth of Cut
Conditions
Machining Process
Machine Limitations
Material
Tool Type
Tool material
Surface Finish
Tolerances

14. Chip Formation Processes
Back rake angle, α
The angle that the tool makes with respect to a vertical from the workpiece
The chip is formed by shearing along the shear plane
The shear plane or shear angle Φ is measured with respect to the horizontal
Flank of the tool is the bottom of the tool not in contact with the material (clearance angle δ)

15. Cutting Definitions

16. Chip Formation

17. Continuous Chip Formation

18. Built Up Edge (BUE) Formation

19. Discontinuous Chip Formation

20. Chip Formation Three Characteristic types of chips Discontinuous
Continuous with built-up edge

21. Three Types of Chips

22. Resulting Finishes of Chip Formation

23. Effect of Shear Angle

24. Summary
Chip formation processes are designed to shear off layers of metal
Control and conditions determine the type of chip formation
The type of formation affects the resulting finish of the workpiece

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