Chip Breakers it's Types, Tool and Uses
What is Chip Breaker?
Chip breakers are features or structures on a cutting tool, such as a drill or endmill, that are designed to improve chip control during machining.
During machining, chips are produced when a cutting tool removes material from a workpiece. These chips can be long, stringy, or otherwise difficult to manage, and can lead to problems such as poor surface finish, tool wear, and even damage to the workpiece.
Chip breakers are designed to help break up these chips, making them shorter and more manageable. They work by interrupting the flow of chips along the cutting edge of the tool, which causes the chips to curl and break into smaller pieces. This helps prevent the chips from becoming tangled around the tool, which can cause damage or breakage. Chip breakers can take many different forms, depending on the type of cutting tool and the material being machined. For example, on a drill bit, chip breakers might take the form of small notches or grooves along the flutes of the bit, while on an endmill, they might be in the form of serrations or other shapes along the cutting edge.
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| Chip Breakers it's Types, Tool and Uses |
Cutting tool is shown on left side of diagram, and the chip breaker is shown on right. The cutting tool has a sharp cutting edge that removes material from the workpiece, while the chip breaker helps to control the chips produced during te machining operation.
The chip breaker is typically located near the cutting edge of the tool, and may consist of a variety of features, such as notches, serrations, or curves. The specific design of the chip breaker depends on the type of tool and the material being machined.
When the cutting tool is in use, the chip breaker helps to break up the chips as they are produced, making them shorter and more manageable. This improves chip control and helps to prevent problems such as tool wear, poor surface finish, and damage to the workpiece.
Types of chip Breakers
There are various types of chip breakers available, each designed for specific machining operations and materials. Some of the common types of chip breakers are:
Straight Chip Breakers: These are simple chip breakers that consist of straight notches along the cutting edge of the tool. They are often used for roughing operations in softer materials such as aluminum.
Serrated Chip Breakers: Serrated chip breakers have a serrated pattern along the cutting edge that helps to break up the chips as they are produced. They are often used in harder materials such as stainless steel.
Helical Chip Breakers: Helical chip breakers are designed with a helix-shaped pattern along the cutting edge that helps to direct the chips away from the workpiece. They are commonly used for drilling and milling operations in materials such as cast iron.
Variable Pitch Chip Breakers: Variable pitch chip breakers have a variable pitch along the cutting edge that helps to break up the chips in a more controlled manner. They are often used in materials that tend to produce long, stringy chips, such as brass and copper.
Curved Chip Breakers: Curved chip breakers have a curved shape along the cutting edge that helps to curl the chips, making them easier to manage. They are commonly used in materials such as titanium and other high-strength alloys.
Wavy Chip Breakers: Wavy chip breakers have a wave-like pattern along the cutting edge that helps to break up the chips and prevent them from becoming tangled. They are often used in materials such as aluminum and plastics.
Chip Breaker Tool
Chip breakers can be found on a variety of cutting tools used in machining operations. Some of the common tools that may incorporate chip breakers are:
Drills: Drill bits often have chip breakers in the form of notches or serrations along the flutes that help to break up chips and prevent them from becoming tangled around the bit.
End mills: End mills are cutting tools used in milling operations, and they may incorporate chip breakers in the form of serrations or other patterns along the cutting edge.
Turning tools: Turning tools are used in lathe operations to remove material from a workpiece. They may have chip breakers in the form of curved or serrated edges that help to control chip formation.
Boring bars: Boring bars are used to enlarge existing holes in a workpiece. They may have chip breakers in the form of notches or grooves along the cutting edge.
Inserts: Inserts are replaceable cutting tips that are used on a variety of cutting tools, such as milling cutters and turning tools. They may incorporate chip breakers in various forms, depending on the specific application.
Uses of Chip Breaker
Chip breakers are used in machining operations to improve chip control and prevent problems that can arise from long or stringy chips. Here are some common uses of chip breakers:
Preventing tool wear: Long, stringy chips can wrap around the cutting tool, causing excessive heat and wear. Chip breakers help to control chip formation, reducing the risk of tool wear and breakage.
Improving surface finish: Long, stringy chips can leave marks on the surface of the workpiece, resulting in poor surface finish. Chip breakers help to produce smaller, more manageable chips, improving surface finish.
Reducing machine downtime: Long, stringy chips can become tangled around the tool, causing machine downtime while the chips are cleared. Chip breakers help to produce shorter chips that are less likely to cause machine downtime.
Improving chip evacuation: Chips that are too long or too large can clog the flutes of a cutting tool, preventing efficient chip evacuation. Chip breakers help to produce smaller chips that are easier to evacuate from the cutting zone.
Preventing workpiece damage: Long, stringy chips can scratch or damage the surface of the workpiece. Chip breakers help to produce shorter chips that are less likely to cause damage.
Overall, chip breakers are an important tool in the machining process, helping to improve chip control and prevent problems that can arise from long or stringy chips.
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