1. Metal Cutting Manufacturing Processes

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

3. Chip Formation Processes ShapingTurningMillingDrillingSawingBroachingGrinding

4. 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 1.Discontinuous 2.Continuous 3.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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