How to interpret types of chips shown in a schematic diagram?

How to Interpret Types of Chips Shown in a Schematic Diagram in the Mold Base Industry

When working in the mold base industry, it is crucial to understand and interpret the types of chips shown in a schematic diagram. These chips can provide valuable information about the manufacturing process and help improve product quality. In this article, we will explore the various types of chips and their interpretations, ensuring a clear understanding of their significance in the mold base industry.

1. Continuous Chips

Continuous chips are characterized by long, continuous curls and are typically associated with ductile materials. When analyzing the continuous chips shown in a schematic diagram, it indicates that the material is being efficiently cut and removed from the workpiece. This suggests that the cutting conditions are optimal, resulting in high productivity and a smooth machining process. Continuous chips are commonly observed in turning operations, where the material is continuously removed along the cutting edge.

2. Discontinuous Chips

Discontinuous chips are fragmented and are mainly found in brittle materials, such as ceramics or some metals. These chips are produced when the material undergoes sudden and localized fractures during the machining process. Analyzing discontinuous chips in a schematic diagram can provide insights into the material's toughness and brittleness. Excessive fragmentation of chips can indicate inappropriate cutting parameters, leading to poor tool life and potential damage to the workpiece.

3. Built-Up Edge (BUE)

Built-Up Edge is a complex chip formation mechanism where material accumulates on the cutting tool during the machining process. It is commonly observed in soft and sticky materials like aluminum. BUE can be identified in a schematic diagram by the presence of irregular and welded chips. The formation of BUE can lead to unpredictable cutting forces, poor surface finishes, and reduced tool life. It is necessary to optimize cutting parameters, such as cutting speed and tool geometry, to prevent or minimize BUE formation in the mold base industry.

4. Serrated Chips

Serrated chips are characterized by a series of small, repetitive notches along the cutting edge. These chips are commonly observed in materials with high strength and low ductility, such as hardened steels. Analyzing serrated chips in a schematic diagram can indicate the material's hardness and toughness. The presence of serrated chips suggests a severe material deformation during the machining process, requiring appropriate cutting parameters, cutting tool selection, and machining techniques.

5. Powder Chips

Powder chips consist of fine particles generated during the machining process. These chips are commonly found in materials with low melting points, like plastics or some non-ferrous metals. Analyzing powder chips in a schematic diagram can provide insights into the material's behavior during machining. Excessive generation of powder chips may indicate the need for proper chip evacuation systems to prevent clogging of the cutting edge and ensure efficient material removal.

Conclusion

In the mold base industry, understanding and interpreting the types of chips shown in a schematic diagram are critical for optimizing the manufacturing process and improving product quality. Continuous chips indicate efficient material removal, while discontinuous chips suggest brittle material behavior. The presence of built-up edge and serrated chips requires careful consideration of cutting parameters to prevent tool wear and ensure surface quality. Powder chips provide valuable information about material behavior during machining and may necessitate proper chip evacuation systems. By analyzing and interpreting the types of chips, professionals in the mold base industry can make informed decisions to enhance productivity, extend tool life, and produce high-quality molds.