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Increase Rake Angle: Enhances chip flow for easier evacuation. Increase Relief Angle: Reduces friction between chips and the tool. Optimize Edge Radius: Alters chip morphology to minimize wrapping.

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Segmented Machining: Especially useful in deep hole applications for adequate chip clearance. Reverse Feed: Alters chip flow direction to minimize wrapping.

Problem: Chip adhesion to the tool and workpiece causes surface finish and performance issues. Standard Materials: Thermoplastics, composites, and some high-performance plastics, which are prone to chip adhesion due to their material properties. Solution: Optimize cutting parameters such as speed and feed rate and use suitable tool coatings (e.g., TiN, TiAlN) to minimize chip adhesion and ensure smoother machining.

Problem: Long strip chips wrapping around the tool. Common Materials: Soft steel, aluminum alloys, and copper, which tend to produce long, stringy chips during machining. Solution: Increase rake and relief angles, use high-pressure coolant, and select a chip breaker tool to break up the chips and enhance chip evacuation on CNC lathes. In cases where hand feed is used, careful control of the feed rate can help produce more minor chips, reducing the likelihood of wrapping.

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Chips pose safety hazards, especially when they are long and stringy. A shop vac or other chip removal system can help prevent chips from accumulating on the machine. Operators should be trained to handle chips safely, using proper protective equipment and techniques to avoid injuries.

Regular machine cleaning and chip removal are essential to prevent buildup, which can lead to chip wrapping. Implementing chip breakers and other control strategies helps maintain a clean work environment. Adjusting feed rates and DOC can improve chip control, resulting in better machining outcomes and extended tool life.

Problem: Chips wrapping around the milling cutter during side milling. Common Materials: Aluminum alloys, soft steel, and copper, which commonly produce long chips in milling operations. Solution: Optimize tool geometry and increase the rake angle to improve chip flow. Ensuring proper coolant application is crucial to producing small chips, which are less likely to wrap around the milling cutter. Selecting milling tools designed for efficient chip control on a CNC lathe can further enhance process stability.

Chips are essential in machining, offering insight into the process when the work zone is obscured by coolant or scratches. The appearance of chips can signal changes, such as the built-up edge (BUE) of the top rake. The shape of chips might reveal whether they break under their momentum or on the part shoulder, avoiding damage to the cutting edge or workpiece surface. Chip size should also fit correctly into tool flutes, slots, grooves, or bores to ensure effective evacuation.

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Long, stringy chips are undesirable, so any tool design aims to break chips by altering their path or curl. Chip breakers can be integrated into the cutting face or added separately. Adjusting the clearance and rake angles plays a significant role in chip formation and control. Grooving tools with specific chip breaker geometries are often tailored to meet the needs of particular applications, reducing cycle time by ensuring smooth chip flow.

Effective chip control is essential for maintaining tool life, improving surface finish, and ensuring safety. Shops can significantly enhance machining performance by implementing chip breakers and high-pressure coolant systems. Regular machine maintenance and cleaning also play a crucial role in preventing chip buildup and ensuring smooth, uninterrupted operations on CNC lathes.

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High-Pressure Coolant: Effectively flushes away chips, preventing wrapping. Lubricating Cutting Fluid: Reduces friction between chips and the tool.

The depth of cut is critical for chip control. Increasing the DOC should be the first corrective action when encountering poor chip control. Proper DOC ensures the formation of tiny chips that are easier to manage.

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Carbide Tools: More wear-resistant, reducing tool wear. Coated Tools: Coatings like TiN or TiAlN minimize chip adhesion.

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In CNC machining, managing chips is crucial for processing efficiency and maintaining the workpiece's surface quality. A common issue is chip wrapping, where elongated chips entangle around the cutting tool or workpiece. This can lead to processing instability, accelerated tool wear, potential workpiece damage, shortened tool life, conveyor disruptions, compromised surface finishes, and heightened safety risks. Materials like stainless steel and aluminum are notorious for generating long, stringy chips, making chip control vital for optimizing performance on CNC lathes.

Problem: Difficulty evacuating chips during deep hole drilling. Common Materials: Soft steel, aluminum alloys, and copper generate long chips that can obstruct the drilling process. Solution: Use drills with chip evacuation grooves, retract the drill regularly to clear chips, and apply high-pressure coolant to facilitate smooth chip removal.

¹ = When we say “abrasive blade”, we don’t mean “abrasive grinding wheel”. Never cut with an abrasive grinding wheel. It will shatter or explode on you if you do.

High-pressure coolant is a highly effective solution for chip control, particularly in CNC lathe operations. The coolant outlets should be positioned as close as possible to the cutting edge, which enhances chip evacuation and reduces heat buildup. This setup is especially beneficial in grooving tools and deep-hole drilling, where chip evacuation can be challenging.

This video, in addition to showing you how to cut hardened steel with an angle grinder, has some valuable safety tips. These tips include how to cut with an abrasive blade¹ without having the blade shatter or break on you. Of course, you don’t have to worry about your blade shattering, breaking or grenading if you cut with a Safety Blade or Safety Blade Grinder/Cutter, because they’re made of solid steel (up to 14″) to prevent such accidents.

Ensuring plenty of support under the insert is crucial for stability, which is critical to a successful process. This stability helps prevent chip wrapping by maintaining consistent contact between the tool and the material.

Problem: Chips wrapping around the tap, causing breakage or incomplete threads. Standard Materials: Aluminum alloys, soft steel, and copper generate problematic chips during tapping. Solution: Apply lubricating cutting fluid to reduce friction, use specialized chip evacuation taps, and adjust cutting speed and feed rate to manage chip formation effectively.

Problem: Chips accumulate in deep holes, leading to wrapping. Standard Materials: Aluminum alloys, soft steel, and copper, which are prone to forming long chips in boring operations. Solution: Use segmented machining techniques and reverse feed strategies to enhance chip flow. Employing a tool holder with a grooving tool designed explicitly for boring can also help break chips into smaller, more manageable pieces.

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Proper cutting-edge alignment is essential for chip control, particularly on CNC lathes. Misalignment can reduce the effectiveness of chip breakers, leading to chip wrapping.

Hardened steel can be tough to cut. According to this video from Ultimate Handyman, that’s because hardened steel is often harder than the steel in hacksaw blades and similar toothed saw blades.

Adjust Cutting Speed: Modifies chip morphology to prevent wrapping. Adjust Feed Rate: Higher feed rates can shorten chips and reduce wrapping.