I don't know if gold dusters have ever encountered this situation. After one hour of processing and half an hour of cleaning, the iron filings always get entangled on the workpiece and the tool. I think it looks like the picture below:
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Are you aware of these chip troubles? Today, the editor will introduce to you the information reflected by chips, as well as some effective chip breaking methods.
01
What are the shapes of chips?
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What chips can tell you:
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Temperature (℃)
Chip color
Temperature (℃)
Chip color
200
light yellow
300
blue
229
tan
320
light cyan
240
brown
350
pewter gray
02
Chip principles and directions
policy
method
be careful
Thicken the chips
Increase feed
Roughness worsens
Tool tip radius becomes smaller
Roughness deteriorates, easy to wear
Increase the leading angle
Reduced tip strength
Curl radius becomes smaller
Use qualified chipbreakers
The cutting resistance becomes high and tool chatter easily occurs.
03
What are the chip breaking methods?
After increasing the feed, the chips become thicker, which is beneficial to chip breaking.
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Increase feed
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depth of cut
The radius of the tool tip fillet becomes smaller and the chip thickness increases.
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Tool nose radius size comparison
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Chip breaking form
Reduce rake angle
Chip compression ratio=hc/h
1. The greater the compression ratio, the easier it is to break chips, but at the same time the cutting resistance also increases.
2. The compression ratio is related to the linear speed vc. When vc decreases, the compression ratio increases, so reducing the linear speed is also beneficial to chip breaking.
3. The rake angle is reduced, the chip deformation is large, and the compression ratio is increased, which is beneficial to chip breaking.
Adopts sharp edge treatment form
It can be seen from the figure that under the same feeding conditions, the blade edge is blunt and sharp, which is beneficial to chip breaking.
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Increasing the main deflection angle makes the chips thicker and facilitates chip breaking.
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The main deflection angle increases
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Chip breaking form
Raised chip breaker
Promote chip breaking
Rubbing against the protrusion of the chip breaker creates a dent on the surface of the chip → significantly increases the chip thickness → promotes chip breaking and is highly damaging.
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Highly damaging
The contact area with the chips becomes smaller and the chips are smoothly discharged due to smooth contact with the protrusions → less damage to the tool.
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The curl radius of the chips becomes smaller
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