1, definition of chipps

Metal swarf
Metal swarf, also known as chips or by other process-specific names (such as turnings, filings,
or shavings), are pieces of metal that are the debris or waste resulting from machining or similar
subtractive (material-removing) manufacturing processes. Metal swarf can be small particles
(such as the gritty swarf from grinding metal) or long, stringy tendrils (such as the springy chips
from turning tough metals).

Various examples of metal swarf, including a block of compressed swarf. Broken up chips are preferred over stringy drill
chips.[1]

Cutting hazards and safety precautions

Metal grinding produces grinding swarf.

Cuts, splinters, punctures, airborne chips

Chips can be extremely sharp, and this creates a safety problem, as they can cause serious
injuries if not handled correctly. Depending on the composition of the material, it can persist in
the environment for a long time before degrading. This, combined with the small size of some
chips (e.g. those of brass or bronze), allows them to disperse widely by piggy-backing on soft
materials and also to penetrate the skin as deep splinters.

It is standard training for machinists, and usually a standing workplace rule, to avoid handling
swarf with bare hands. Similarly, it is also standard training for machinists, and usually a
standing workplace rule, to minimize or entirely avoid handling swarf by blowing chips away with
compressed air, but this practice can potentially damage the machine by causing chips to get
jammed in and then embedded into the moving surfaces leading to degradation of the
machine's precision. Alternatives to blowing chips away include vacuuming them away with an
industrial vacuum (shop vacuum); gently washing them away with a coolant hose discharging at
typical garden-hose pressures; or preventing their generation in the first place (for example,
forming threads instead of cutting them). Some machine tool manuals proscribe these practices
both for safety and for the preservation of way wipers and bearing seals.

It is not uncommon for chips flying off the cutter to be ejected with great force and to fly several
metres. These flying chips present a hazard that is deflected with safety glasses, face shields,
and other personal protective equipment, as well as the sheet-metal enclosures (and
polycarbonate windows) that surround most commercial computer numerical control (CNC)
machine tools.
Flammability

Due to its high surface area, swarf composed of some reactive metals can be highly flammable.
Caution should be exercised to avoid ignition sources when handling or storing swarf in loose
form, especially swarf of pure magnesium, magnesium alloy, pure titanium, titanium alloy, iron,
and non-stainless steel.

Swarf stored in piles or bins may also spontaneously combust, especially if the swarf is coated
with cutting oil.[2]

To extinguish swarf fires, a special fire extinguisher is needed, designed for fighting Class D
(metal) fires.

Toxicity

Some common engineering materials such as beryllium are hazardous when finely divided and
appropriate measures should be taken to prevent exposure.

Chip breaking

Optimum cutting efficiencies often generate long spring-like swarf. This is hard to deal with as it
is bulky and can clog the nozzle of a shop vac. Clean-up and disposal of this continuous-cutting
swarf is made simpler by using a cutting tool with a chip-breaker. This results in denser, more
manageable waste. Chip breaking tool geometry is generally designed to break the chip by
having it curl back onto itself. This action produces many small spiral shaped rings instead of
one long helical chip. "Number Nine" shaped chips or short swarf in general are preferred also
because it helps prevent entangling the rotating machine.

Machine cleaning and chip handling

Disposing of swarf is a tedious but necessary task. For ease of transport and handling, swarf
may be compressed into bricks, which greatly reduces associated problems with storing and
cost; it also improves material handling for all concerned with its reclamation and recycling.
 Recycling

Metal swarf can usually be recycled, and this is the preferred method of disposal due to the
environmental concerns regarding potential contamination with cutting fluid or tramp oil.

2,Formation of chipps on metal

In any machining operation, the material is removed from the workpiece in the form of chips,
the nature of which differs from operation to operation. As the form and dimensions of a chip
from any process can reveal lot of information about the nature and loyalty of process, the
analysis of chip formation is very important. Chips are formed due to tearing and shearing.
In the process of chip formation by tear, the workpiece material adjacent to tool face is
compressed and a crack runs ahead of cutting tool and towards the body of the workpiece. The
chip is highly deformed and workpiece material is relatively under-formed. Cutting takes place
intermittently and there is no movement of the work-piece material over the tool face. In chip
formation by shear, there is general movement of the chip over tool face.

As the tool advances into the work-piece, the metal ahead of the tool is severely stressed. The cutting
tool causes internal shearing action in the metal, such that the metal below the cutting edge yields
and flows plastically in the form of chip. Firstly compression of the metal under the tool edge takes
place and then follows separation of metal, when compression limit of that metal has been exceeded.
Plastic flow takes place in a localized region called shear plane, which extends from the cutting edge
obliquely upto the uncut surface ahead of the tool. When the metal is sheared the crystals are
elongated, the direction of elongation being different than from that of the shear.
As the tool advances into the work-piece, the metal ahead of the tool is severely stressed. The cutting
tool causes internal shearing action in the metal, such that the metal below the cutting edge yields
and flows plastically in the form of chip. Firstly compression of the metal under the tool edge takes
place and then follows separation of metal, when compression limit of that metal has been exceeded.

Plastic flow takes place in a localized region called shear plane, which extends from the cutting edge
obliquely upto the uncut surface ahead of the tool. When the metal is sheared the crystals are
elongated, the direction of elongation being different than from that of the shear. As the tool
advances into the work-piece, the metal ahead of the tool is severely stressed. The cutting tool causes
internal shearing action in the metal, such that the metal below the cutting edge yields and flows
plastically in the form of chip. Firstly compression of the metal under the tool edge takes place and
then follows separation of metal, when compression limit of that metal has been exceeded.

Plastic flow takes place in a localized region called shear plane, which extends from the cutting edge
obliquely upto the uncut surface ahead of the tool. When the metal is sheared the crystals are
elongated, the direction of elongation being different than from that of the shear.

3, type of chipps
When metals are finished in manufacturing industries through the machining process than metal
chips are produced. These metal chips may be of different types. The chips formed depend upon the
types of materials used and other factors too. Here we will discuss them in detail.

During the machining process of the workpiece to give it the desired shape, metal chips are
produced. The chips formed may be of continuous, discontinuous and continuous with built-up edge
type. The types of chips formed in the machining process depend upon so many factors, we will
discuss it later. Basically there are three types of chips produced in the metal machining and these
are continuous, discontinuous and continuous with built-up edge.
Types of Chips

The various types of chips in metal cutting are

1. Continuous chips
2. Discontinuous chips &
3. Continuous chips with built-up edge (or BUE chips)
Let’s discuss about them one by one

1. Continuous Chips

If the metal chips formed during machining is without segments i.e. without breakage, then it is
called as continuous types of chips.
Continuous chips are formed when the ductile material is machined with high cutting speed and
minimum friction between the chip and tool face.

The conditions which are responsible for the formation of continuous types of chips are

 Ductile material like mild steel is used.

 The bigger rake angle of the tool.
 High cutting speed.
 Minimum friction between the chip and tool interface.
 Small depth of cut.
Advantages

The formation of continuous chips during machining process has the following advantages

 Better surface finish to the ductile material.

 Less heat generation due to minimum friction between the tool face and chip.
 Low power consumption.
 Long tool life due to less wear and tear.
2. Discontinuous Chips

If the chips formed during machining process is not continuous i.e. formed with breakage is called
discontinuous chips.

Discontinuous types of chips are formed when hard and brittle metals like brass, bronze and cast
iron is machined.
Conditions which are responsible for the formation of discontinuous chips are:

 Low feed rate.

 Small rake angle of the tool.
 High cutting speed.
 High friction forces at the chip tool interface.
 Too much depth of cut.
Advantages

The formation of discontinuous types of chips in brittle materials provides good surface finish,
increases the tool life and reduces the consumption of power.

Disadvantages

When discontinuous chips are formed in the ductile materials, the workpiece result in poor surface
finish and excessive wear and tear of the tool takes place

3. Continuous Chips with Built Up Edge

Continuous chips with built up edge is formed by machining ductile material with high friction at the
chip-tool interface.

It is similar to the continuous types of chips but it is of less smoothness due to the built up edge.
How Built Up Edge is Formed?

When the chip is flows in upward direction and high friction is exist in between the interface of the
chip and tool. Due to the high friction between the chip and tool a very intense heat is generated at
the nose of the tool.  The compressed metal adjacent to the tool nose gets welded to it. This
compressed metal welded to the nose is called built up edge. When the chip flows through this built
up edge, it gets broken and carried away by the chip and called as built up edge chips, the rest of
the built up edge is adhere to the surface of the workpiece and makes it rough.

Due to formation of the built up edge the rake angle of the tool gets changed and so is the cutting
force.

The factors which are responsible for promoting the formation of the BUE chips are:

 Excessive feed rate.

 The small rake angle of the tool.
 Low cutting speed.
 Lack of coolant and this increase the friction between the chip tool interfaces.
Advantages

The making of the BUE has one advantage i.e. it protects the tool from getting damaged from high
friction and temperature generated during the machining process and hence the tool life increases.

Disadvantages

The formation of these types of chips results in rough surface finish, change in the rake angle and
cutting forces.

Continuou
Continuou Discontinuou
s chips
s s
S.no Factors with Built

Chips Chips Up Edge

(BUE)

Material Brittle, ductile

1. Ductile Ductile
types but hard

2. Rake Large Small Small

 angle

Cutting Medium or Low or

3. High
speed high medium

Friction
between
chip
4. Minimum Maximum Maximum
tool
interfac
e

Depth of
5. Small High Medium
cut

This is all about the different types of chips in metal

cutting.