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Answer each of the following: (i) Distinguish, with examples, between continuous and discontinuous chips produced by metal cutting - Leaving Cert Engineering - Question a - 2020
Question a
Answer each of the following: (i) Distinguish, with examples, between continuous and discontinuous chips produced by metal cutting. (ii) Explain the impact of a co... show full transcript
Worked Solution & Example Answer:Answer each of the following: (i) Distinguish, with examples, between continuous and discontinuous chips produced by metal cutting - Leaving Cert Engineering - Question a - 2020
Step 1
Distinguish, with examples, between continuous and discontinuous chips produced by metal cutting.
Answer
Discontinuous Chips
Discontinuous chips are small segments produced by metal cutting processes. They usually fracture without significant deformation and are often associated with brittle materials such as brass, bronze, and cast iron. These chips are effective in cutting materials that are brittle but can result in poor surface finishes and excessive wear on cutting tools due to their tearing action on ductile materials.
Example: When cutting brass, the chips might break into small fragments due to the material's brittle nature.
Continuous Chips
Continuous chips are formed during metal machining in long ribbons without breaking. This type of chip formation is characterized by high cutting speeds and minimal friction between the tool face and ductile materials. Continuous chips are typically associated with materials such as mild steel and aluminum.
Example: Machining aluminum at high speed often results in long, continuous chips.
Step 2
Explain the impact of a continuous chip on an automated machining process.
Answer
Continuous chips are effectively generated by machining at high speeds and low feed rates. This provides a smooth cutting action with minimal wear and tear on the machine. However, excessive feed rates can lead to increased heat, excessive wear on the tool, and the formation of a built-up edge with ineffective cutting. The presence of long, continuous chips can clog automated machines and pose safety hazards, as they may entangle with moving parts.