How to control and analyze chips in the process of milling and turning composite machining?

During the milling and turning process, the chips undergo severe deformation in the deformation zone, resulting in increased hardness, decreased plasticity, and brittle performance. In the process of chip discharge, when encountering obstacles such as the back face of the tool, the transition surface of the workpiece, or the surface to be machined, if the strain in a certain part exceeds the fracture strain value of the chip material, the chips will break. ​ The greater the brittleness of the workpiece material (lower fracture strain value), the greater the cutting thickness, and the smaller the cutting curl radius, the easier it is for the chips to break. The following measures can be taken to control chips: 1. Use a chip breaker groove. By setting up a chip breaker to apply a certain constraint force to the chips in the flow, the chip strain increases and the chip curling radius decreases. 2. Change the angle of the cutting tool. Increasing the main angle of the cutting tool increases the cutting thickness, which is beneficial for chip breaking. Reducing the rake angle of the tool can increase the deformation of the chips, making them more prone to breakage. The inclination angle of the blade can control the flow direction of the chips. When the inclination angle is positive, the chips often curl and collide with the rear blade surface to break, forming C-shaped chips or naturally flowing out to form spiral chips; When the inclination angle of the blade is negative, the curled chips often collide with the machined surface and break, forming C-shaped chips or hexagonal chips. Adjust the cutting amount. Increasing the feed rate F increases the cutting thickness, which is beneficial for chips; But increasing F will increase the roughness value of the processed surface. Appropriately reducing the cutting speed to increase deformation is beneficial for chip breaking, but it will reduce the cutting efficiency of the material. The cutting amount should be selected appropriately according to the actual conditions of Foshan turning milling composite machining.