A hybrid algorithm for predicting chip form/chip breakability in machining

Prediction of chip breakability for a wide range of machining conditions is a difficult task. Currently available predictive machining theories are not suitable for use in the shop floor environment. The methodology presented in this paper provides a new and viable means to predict chip breakability and chip shapes/sizes in machining process planning systems. Due to the extreme difficulty involved in developing a numerical model for predicting chip breakability for a wide range of machining conditions, including work materials, tool geometry, chip-breakers and cutting conditions, this paper presents a hybrid algorithm-based model to characterize various chip shapes and sizes, and to quantify the chip form/chip breakability based on a chip control reference database developed through a set of systematic machining experiments. The chip form and chip breakability could then be predicted with reasonable accuracy for a given set of machining conditions using this new algorithm in conjunction with the chip control reference database.