Analysis of Chip Removal Operations via New Quick-Stop Device

Abstract

Machining is obviously indispensable to industrial manufacture, a process whereby a workpiece takes its planned shape after proper chip removal. The type and the size of a chip from such a process are determined by a set of factors, the analysis of which can provide valuable insights into the cutting process. In this study, a new quick-stop device (QSD) for chip removal was designed, manufactured, and employed in an analysis of chip formation in chip removal with cutting tool at varying cutting speeds. The samples competently illustrate the differences in the formation of chips at various cutting speeds. Depending on material and cutting conditions, a chip may be continuous or discontinuous. Employing metallographic techniques, the present study analyzed the orthogonal cutting of aluminum 5000 with cutting tool. During the experiments, the built-up edges (BUEs), the surface quality, and the interactions among machining parameters were observed. At the end, a frozen chip with a BUE was divided into seven sections. The results show that the new QSD is effective and BUEs have a direct effect on the quality of a workpiece's surface and additionally can increase the penetration depth and machining forces.