what causes built-upedge

During machining, some of its own parts are removed. After machining, it may partially stick on the chip and the machined surface. This results in poor surface finishing. However, it gives a poor surface finish it also reduces the tool wear and increases the tool life because it acts as an additional layer over the tool cutting edge

The other names of serrated chips are serrated chips and non-homogeneous chips. This chip has a saw tooth appearance due to an alternating large zone of high shear strain followed by a small zone of low shear strain. Due to this cyclic chip formation, it becomes semi-continuous. This type of chip formation occurs while machining the difficult-to-machine materials (such as titanium alloys, nickel-based superalloys, and austenitic stainless steel) at high cutting velocities.

Built up edgein metal cutting

Chip breakers are equipped along with the cutting tool, to avoid the chip tangling about the tool. This usually happens in the turning process.

Continuous chips are in the form of a ribbon-like structure (long coil) with the same thickness throughout the length. This kind of chip is formed while cutting the ductile material (such as low carbon steel, copper, brass, and aluminum alloys) at high cutting velocities and pressure of the tool cutting edge in compression and shear. This makes the material ahead of the tool cutting edge. Sharp cutting edge and low friction on the tool-chip interface also plays a major part in this chip formation.

Overall, the formation of a continuous chip results in a good surface finish and smooth cutting. It also increases the tool life and decreases power consumption.

Types of chips in metal cutting

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While comparing continuous chip, discontinuous chips are easy to handle because of its short length. Also, it can be easily disposed off.

Discontinuous chips

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While machining the brittle materials (such as cast iron, bronze, and high carbon steel) at low cutting velocities the chips are formed in discontinuous segments. These segments are attached loosely to each other. During deformation, the material lacks its ductility and it attains fracture simultaneously periodic ruptures occur on the chip flow. During this chip formation, the cutting forces vary frequently.

Bestcontinuous chip with built up edge

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Stiffness of the cutting tool and holding devices plays a major role in discontinuous chip formation because improper stiffness may cause vibration, dimensional inaccuracy, poor surface finish, and even damage the cutting tool.

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Built up edgechips

While machining the soft metals at low speed and low rake angles, distortion occurs on the machined surface. So it gives unfavorable results while machining the soft metals.

The sheared material that flows along with the cutting tool surface in the form of small pieces during metal cutting is called a chip. Chip actually has two surfaces such as a shiny surface (which has contact with the rake surface of the tool) and other is a rough surface (which has no contact with any solid body). The basic types of chips produced in orthogonal cutting are

These types of chips are formed during metal cutting. The chip formation during metal cutting is based on various factors such as,

Built up edgeformation

Discontinuouschipformation

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.During the cutting process, the friction between the tool-chip interfaces are high and it makes the chip material weld itself to the tool rake surface near the tooltip which is called a build-up edge (BUE). It may be severe when the chip continuously rubs the tool surface. It acts as a cutting edge of the tool. The formation of the build-up edge is temporary and unstable.

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The deformation zone ahead of the cutting edge is called a primary deformation zone. Due to the friction at the tool chip interface, the work material gets additional deformation and this zone is called the secondary deformation zone. The thickness of this zone is directly proportional to the friction.