TYPES OF CHIPS

Irrespective of cutting conditions, chips produced will be from

the following types:
1. Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up Edge (BUE)
4. Serrated chip

DISCONTINUOUS CHIPS
Also called segmented chips
Produced while cutting brittle work materials (e.g.,
cast irons, bronze, hard brass)
Material ahead of the tool edge fails in brittle fracture
This produces small fragments of discontinuous chips
Also produced while cutting ductile materials under
following conditions:

Small tool rake angle

Low cutting speeds
Large feed and depth of cut
High tool-chip friction

CONTINUOUS CHIPS
Produced while machining more ductile
materials (e.g., low carbon steel)
It is most desirable as it ensures stable cutting
Produced under following conditions:

High cutting speeds

Small feeds and depths
Large rake angle of tool
Sharp cutting edge on the tool

Chips are difficult to handle & dispose

Chips coil or curl around tool
May injure operator
It remains in contact with tool face for longer
period (friction)
Chip breakers may be used to break the chips

CONTINUOUS CHIPS WITH BUE

Produced while machining ductile
materials under following
conditions:
High local temperatures
Extreme pressure in cutting zone
High friction in tool chip interface
Low-to-medium cutting speeds

Tool-chip friction causes portions

of chip to adhere to rake face
BUE formation is cyclical; it forms,
then breaks off

SERRATED CHIPS
Semicontinuous - saw-tooth
appearance
Cyclical chip formation of alternating
high shear strain then low shear strain
Most closely associated with difficultto-machine metals at high cutting
speeds

CUTTING FLUIDS

FUNCTIONS OF CUTTING FLUIDS

To cool the cutting tool and workpiece
To lubricate the cutting tool and reduce the coefficient
of friction between the chip and tool
To improve surface finish
To reduce tool forces thereby reducing power
consumption during cutting
It causes the chips to break up into small pieces
It washes away the chips from the tool
It prevents corrosion of work and machine
Removal of heat from the cutting zone prevents
thermal distortion and improves dimensional stability

PROPERTIES OF CUTTING FLUIDS

A cutting fluid should possess the following properties:
It should have high specific heat, high heat conductivity and
high film coefficient
It should possess good lubricating properties to reduce
frictional forces and to decrease power consumption
It should be odorless
It should be non corrosive to work and machine
It should be non toxic to operating personnel
It should have low viscosity to permit free flow of the liquid
It should be stable in use and storage
It should permit clear view of work while machining
It should be safe with regards to fire and accident hazards

TYPES OF CUTTING FLUIDS

All the cutting fluids can be divided into two groups:
Water based fluids
Straight or neat oil based fluids
Most commonly used cutting fluids
Either aqueous based solutions or cutting oils
Fall into three categories
Cutting oils
Emulsifiable oils
Chemical (synthetic) cutting fluids

CUTTING OILS
Two classifications
Active
Inactive

Terms relate to oil's chemical activity or ability

to react with metal surface
Elevated temperatures
Improve cutting action
Protect surface

ACTIVE CUTTING OILS

Those that will darken copper strip immersed
for 3 hours at temperature of 212F
Dark or transparent
Better for heavy-duty jobs
Three categories
Sulfurized mineral oils
Sulfochlorinated mineral oils
Sulfochlorinated fatty oil blends

INACTIVE CUTTING OILS

Oils will not darken copper strip immersed in
them for 3 hours at 212F
Contained sulfur is natural
Termed inactive because sulfur so firmly attached
to oil very little released

Four general categories

Straight mineral oils, fatty oils, fatty and mineral
oil blends, sulfurized fatty-mineral oil blend

WATER BASED CUTTING FLUIDS

These oils are soluble in water
Soluble oil (1 to 5 %) is mixed with water to form an
emulsion
This has excellent cooling properties at low cost along
with lubrication effect
Modern soluble oils contain corrosion inhibitor and a
biocide to keep down the bacteria growth
Soda solutions are often used on grinding operation as
it has good flushing action and cooling effect
Utmost care should be taken when water based
coolants are used while cutting with carbide inserts

STRAIGHT/NEAT OIL BASED CUTTING

FLUIDS
Usually these fluids are undiluted
However, most of the oils are mixtures of oils or oils with
chemicals (sulphur and chlorine)
They are classified into:
Mineral oils
Straight fatty oils
Compounded or blended oils
Chlorinated oils

STRAIGHT/NEAT OIL CUTTING FLUIDS

1. Mineral Oils
Composed of hydro carbons of different structures and molecular weights
These oils are normally used for light machining operations such as turret
and capstan lathes and single spindle automats
2. Straight fatty Oils
Most important variety is lard oil
These oils are not stable and rapidly lose their lubrication properties
They have high viscosity and hence are not satisfactory coolants
Mainly used during thread cutting with taps and dies
They are more expensive

STRAIGHT/NEAT OIL CUTTING FLUIDS

3. Compounded or Blended Oils
These are mixtures of minerals and fatty oils
Its film strength is retained even when diluted with 75% mineral oil
Suitable for heavy duty operations such as threading on capstan and turret
lathes, thread milling and medium capacity automatic lathes
4. Sulphurised Oils
Also called Extreme Pressure (EP) oils
Sulphur is mixed (about 5%) in lard oil
Used for heavy duty lathe work, gear cutting and thread grinding
Depending upon form of sulphur added three types of EP sulphurised oils
are
Those containing combined sulphur
Those containing free sulphur
Those containing both combined and free sulphur

STRAIGHT/NEAT OIL CUTTING FLUIDS

5. Chlorinated Oils
When chlorine is added in mineral oils, it is called chlorinated cutting oil
When both chlorine and sulphur are present in oil, they give extreme
pressure property
It makes suitable for machining of strong and tough materials (stainless
steel, nickel alloys etc)

METHODS OF APPLICATION
4 basic methods:
1. Flooding
2. Mist
3. High-pressure
systems
4. Through the cutting
tool system

SELECTION OF CUTTING FLUID

Selection of particular type of cutting fluid depends upon
Cutting speed
Feed rate
Depth of cut
Cutting tool material
Workpiece material
Velocity of cutting fluid
Expected cutting tool life
Cost of cutting fluid
The life of cutting fluid and loss of cutting fluid during
operation

COOLANTS & LUBRICANTS

Generally following coolants & lubricants may be used for
machining different metals:
Metals

Coolants/Lubricants

Steels & Wrought Iron

Water soluble oils,

Sulphur based and mineral oils

Aluminium

Mineral oils and fatty oils,

Soluble oils

Brass, Copper, Bronze monel

metal and malleable iron

Soluble oils

Cast Iron

Machined dry

CUTTING FLUIDS USED

Material

Turning

Tapping

Drilling

Cast Iron

Machined Dry

Machined Dry or
25% lard oil+75%
mineral oil

Machined Dry

Tool and low

carbon steels

25% to 70% lard +

mineral oil

20 to 405 lard oil +

mineral oil

Soluble oil with

95% water

Alloy Steel

25% Sulphur base

oil + 75% mineral
oil

30% lard oil+ 70%

mineral oil

Soluble oil with

80% water

Copper

Soluble oil with 90 to 95 % water

Aluminium

Mineral oil with

10% soluble oil

Lard oil

Soluble oil with 75

to 90% water

COOLANTS & LUBRICANTS

The fluid that finds its way into asperities between chip and tool
in the vicinity of tool point is subjected to the following unique
combination of conditions:
High local temperature
High local pressure approaching the hardness of the metal cut
Smooth surface produced
Highly stressed metal

CHARACTERISTICS
Cutting Fluid

Cooling Properties

Lubricating
Properties

Anti-welding
Properties

Water

Excellent

Poor

Poor

Mineral Oil

Fairly Good

Good

Fair

Fatty Oil

Fair

Excellent

Fair

E.P Cutting Oil

Fair

Good

Excellent

LUBRICANTS
Solid lubricants are used in as suspension in liquid vehicle by means of
depression agent
A lubricant should possess following properties
It should contain suitable reactive ingredients that on reaction with
the work material forms a compound of lower shear strength
It should be sufficiently unstable to be broken down under the
temperature and pressure existing at the chip tool interface
It should have a small molecular size in order to allow rapid
diffusion and penetration to the chip tool interface
It should maintain conventional hydrodynamic film between the
chip and the tool face
Ex. Carbon tetrachloride (CCl4), Chloroform (CHCl3), Trichloroethane
(CH3CCl3)