Types of Chip Formation

Various types of chips, which are formed in various cutting conditions and type of machining, can be categorized as follows:

• Continuous chip.
• Discontinuous chip.
• Continuous Chip with built-up Edge

Figure 19.1 Types of Chip Formation in Metal Cutting

Continuous Chip: Continuous chip, as shown in Figure 19.1(a), is formed due to

• Machining of ductile materials.
• Small undercut thickness.
• High cutting speed.
• Large rake angle of the tool.
• Suitable cutting fluids.

Discontinuous Chip: Discontinuous chip, as shown in Figure 19.1 (b), is formed due to

• Machining of brittle work materials.
• Low cutting speed.
• Small rake angle.
• Large uncut chip thickness.

Continuous Chip with Built-up (BUP) Edge: Continuous chip with built-up edge, as shown in Figure 19.1 (c), is formed due to

• Large friction or stronger adhesion between chips and tool face.
• Low rake angle.
• Large uncut chip thickness.