Hey there! As a supplier of carbide flat cutters, I've been getting a lot of questions about the chip formation process when using these bad boys. So, I thought I'd sit down and share what I know with you all.
First off, let's talk a bit about carbide flat cutters. These cutters are made from carbide, which is a super-hard material that can withstand high temperatures and pressures. They're commonly used in machining operations to cut through various materials like metal, wood, and plastic. The flat design of these cutters allows for efficient and precise cutting, making them a popular choice in many industries.
Now, onto the main topic: the chip formation process. When a carbide flat cutter is used to cut a material, the cutting edge of the cutter comes into contact with the workpiece. As the cutter rotates and moves forward, it applies a force to the material, causing it to deform. This deformation leads to the formation of chips.
There are three main types of chip formation: continuous chips, segmented chips, and discontinuous chips.
Continuous Chips
Continuous chips are formed when the material being cut deforms plastically in a continuous manner. This usually happens when cutting ductile materials like aluminum or mild steel. The cutting process is smooth, and the chips come off in long, continuous ribbons. The formation of continuous chips is generally considered ideal because it indicates a stable cutting process. However, continuous chips can sometimes cause problems if they get tangled around the cutter or the workpiece. To prevent this, coolant or lubricant is often used to help break up the chips and flush them away.
Segmented Chips
Segmented chips are a bit different. They're formed when the material experiences a combination of plastic deformation and fracture. This type of chip formation is common when cutting materials with medium ductility, such as some types of stainless steel. The chips are made up of segments that are connected by thin bridges. Segmented chips can be an indication of a less stable cutting process compared to continuous chips. The formation of these chips can lead to fluctuations in the cutting force, which may affect the surface finish of the workpiece.
Discontinuous Chips
Discontinuous chips are formed when the material fractures into small, separate pieces during the cutting process. This is typical when cutting brittle materials like cast iron or some hard plastics. The chips are irregular in shape and size. Discontinuous chips are often a sign that the material is not deforming plastically as much as in the case of continuous or segmented chips. The cutting process can be quite rough, and the surface finish of the workpiece may be poor. However, discontinuous chips are easy to handle as they don't tend to get tangled.
Now, let's talk about how the design of the carbide flat cutter affects chip formation. The number of flutes on the cutter plays a crucial role. For example, a 2 Flutes Flat End Mill is often used when more chip space is required. The fewer flutes mean there's more room for the chips to escape, which is beneficial when cutting materials that produce large chips, like aluminum. On the other hand, a 65HRC 4 Flutes Flat End Mill can provide a better surface finish because it has more cutting edges. The increased number of flutes allows for a finer feed per tooth, which results in a smoother cut. However, with more flutes, there's less space for the chips, so it's important to use the right cutting parameters and coolant to ensure proper chip evacuation.
The geometry of the cutter, such as the rake angle and the clearance angle, also affects chip formation. A positive rake angle reduces the cutting force and makes it easier for the cutter to penetrate the material, which can lead to the formation of continuous chips. A negative rake angle, on the other hand, increases the cutting force but can be beneficial when cutting hard materials as it provides more strength to the cutting edge. The clearance angle is important for preventing the cutter from rubbing against the workpiece, which can cause excessive heat and wear.
Another factor that influences chip formation is the cutting speed, feed rate, and depth of cut. These parameters need to be carefully selected based on the material being cut and the type of cutter being used. For example, a higher cutting speed can sometimes lead to the formation of continuous chips, but it also increases the heat generated during the cutting process. If the cutting speed is too high, it can cause the cutter to wear out quickly or even break. The feed rate determines how much material is removed per revolution of the cutter. A higher feed rate can increase the productivity but may also affect the chip formation and the surface finish of the workpiece.
As a carbide flat cutter supplier, we offer a wide range of products to suit different cutting needs. Our Flooring & V Joint Set is perfect for creating precise joints in flooring materials. Whether you're a professional machinist or a DIY enthusiast, we've got the right cutter for you.
If you're interested in learning more about our carbide flat cutters or have any questions about the chip formation process, don't hesitate to get in touch. We're always happy to help you find the best solution for your cutting applications. Whether you need advice on selecting the right cutter or want to discuss your specific project requirements, we're here to assist you. Contact us today to start a conversation about your procurement needs.
References
- Kalpakjian, S., & Schmid, S. R. (2009). Manufacturing Engineering and Technology. Pearson Prentice Hall.
- Trent, E. M., & Wright, P. K. (2000). Metal Cutting. Butterworth-Heinemann.
