Development of web-based machining chip breaking prediction systems

  • Li Zhou
  • Yiming RongEmail author
  • Zhenjia Li
  • Juhchin A. Yang
Original Article


The prediction of chip breaking in machining is an important task of automated manufacturing. A chip breaking predictive model has been developed to predict the chip breaking behaviour in steel turning with grooved tools. The model is based on the chip breaking limits theory. A web-based chip breaking prediction system has been developed and presented in this paper with industrial application examples. With the system, the chip breaking range in steel turning with grooved tools can be predicted under different cutting conditions. The experimental data for turning different steel material over a wide range of feed rates, cutting speeds and tool geometry showed agreements with the model prediction. The user-friendly system is accessible through the Internet for the purposes of cutting condition design and tool selection. Also, the system can easily be extended to contain new cutting tools and new workpiece materials with a small number of cutting tests.


Chip breaking Web-based Chip breaking limits 



Feed rate (mm/rev)


Depth of cut (mm)


Cutting speed (m/min)


The critical feed rate (mm/rev)


The critical depth of cut (mm)


Insert Nose radius (mm)


Insert chip breaking groove width (mm)


Cutting edge angle (deg)


Insert rake angle (deg)


Insert land rake angle (deg)


Insert/chip restricted contact length (mm)


Insert inclination angle (deg)


Insert backwall height (mm)


Work piece




  1. 1.
    Stabler VG (1964) The chip flow law and its consequence. In: Proceedings of the 5th International Machine Tool Design and Research Conference, Birmingham, UK, pp 243–251Google Scholar
  2. 2.
    Colwell LV (1954) Predicting the angle of chip flow for single point cutting tools. Trans ASME 76(2):199–202Google Scholar
  3. 3.
    Jiang CY, Zhang YZ, Chi ZJ (1984) Experimental research of the chip flow direction and its application to the chip control. Annals CIRP 33:81–84Google Scholar
  4. 4.
    Pekerlharing AJ (1964) Why and how does the chip curl and break. Annals CIRP 12:144–147Google Scholar
  5. 5.
    Jawahir IS (1988) The tool restricted contact effect as a major influencing factor in chip breaking. Annals CIRP 37:121–126Google Scholar
  6. 6.
    Nakayama K (1972) Origins of side curl in metal cutting. Bullet Japan Societ Precis Engin 6(3):99–101Google Scholar
  7. 7.
    Nakayama K (1984) Chip control in metal cutting. Bullet Japan Societ Precis Engin 18(2):97–103Google Scholar
  8. 8.
    Chen Y, Shi H (1993) Curling and flowing of 3-D chips. J Huazhong Univ Sci Technol 21(4):1–6Google Scholar
  9. 9.
    Jawahir IS (1990) On the controllability of chip breaking cycles and modes of chip breaking in metal machining. Annals CIRP 39:47–51Google Scholar
  10. 10.
    Zhang YZ (1980) Chip curl, chip breaking, and chip control of the difficult-to-cut materials. Annals CIRP 29:79–83Google Scholar
  11. 11.
    Nakayama K (1962) A study on chip-breakers. Bullet Japan Societ Mechan Engin 5(17):142–150Google Scholar
  12. 12.
    Spaans C, van Geel PFHJ (1970) Breaking mechanisms in cutting with a chip breaker. Annals CIRP 18:87–92Google Scholar
  13. 13.
    Jawahir IS, van Luttervelt CA (1993) Recent developments in chip control research and applications. Annals CIRP 42:659–685Google Scholar
  14. 14.
    Worthington B, Rahman MH (1979) Prediction breaking with groove type breakers. Int J Mach Tool Design Res 19:121–132CrossRefGoogle Scholar
  15. 15.
    Li Z, Rong Y (1999) Study on chip breaking limits in machining. J Machin Sci Technol 3(1):25–48Google Scholar
  16. 16.
    Zhou L (2002) Machining chip-breaking prediction with grooved inserts in steel turning. Dissertation, Worcester Polytechnic InstituteGoogle Scholar

Copyright information

© Springer-Verlag London Limited 2003

Authors and Affiliations

  • Li Zhou
    • 1
  • Yiming Rong
    • 1
    Email author
  • Zhenjia Li
    • 2
  • Juhchin A. Yang
    • 3
  1. 1.Worcester Polytechnic InstituteUSA
  2. 2.Harbin University of Science and TechnologyChina
  3. 3.Ford Motor CompanyUSA

Personalised recommendations