The effect of chip breaker geometry on chip shape, bending moment, and cutting force: FE analysis and experimental study

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

“…This necessitates restrictive cutting conditions to be identified and rigorously applied [11,12]. In addition, an appropriate design of a cutting tool is essential to achieve an effective chipping operation and to extend tool life [13,14]. However, chip evacuation is a recurrent problem that needs addressing with machining ductile and soft materials, especially with the formation of continuous chips [10,15,16].…”

“…This results in a higher number of production stops and, therefore, in a dramatic increase of production time. Thus, the chip formation process and chip control using combined cryogenic and minimum quantity lubrication [19,20], applying cryogenic lubrication [7,21], high pressure coolant [2,11] ultrasonic-assisted vibration [15,17], optimization of the processing parameters [10,[22][23][24], and chip breakers [10,14,16] as well as their limitations [25], have been widely studied, both experimentally and by means of simulation. It is widely accepted that the contribution of chip breakers in enhancing the chip fragmentation process is significant.…”

“…This makes it critical to control the chip evacuation process, which can be satisfactorily achieved using proper chip breaker geometry to bend the generated chip sufficiently so that it breaks on its own. Researchers have studied different methodologies to optimize chip breakers design, experimentally [16] and combining experimentation and simulation [14,31], but most of them restricted their work to non-PCD insert tools. On the other hand, the authors previously worked on developing chip breakers for PCD inserts welded into milling-tools [14].…”

“…Researchers have studied different methodologies to optimize chip breakers design, experimentally [16] and combining experimentation and simulation [14,31], but most of them restricted their work to non-PCD insert tools. On the other hand, the authors previously worked on developing chip breakers for PCD inserts welded into milling-tools [14]. One of the main issues was the implementation of a simulation tool to model the processing of PCD by a ns-pulsed laser.…”

Effect of longitudinal−torsional vibration in ultrasonic-assisted drilling

“…During cutting these materials, chip forms continuously in helical coil shape causing chip clogging in the drill flutes. This event might be effective on surface quality, tool wear acceleration and built-up edge generation [7][8][9]. To overcome these problems, some researchers proposed a couple of solutions.…”