Analysis of chips formation in subtractive manufacturing for working safety

Abstract

Subtractive manufacturing is the most implemented for metal processing to make products in the world. Chips formation is the distinctive characteristic of subtractive. There are three types of chips in general which are: continuous, serrated and discontinuous. Characteristics of chips are affected by some factors including the characteristics of materials, cutting parameter and cooling fluid. Size and type of chips have effects in cutting tool lifetime and further to the machine lifetime itself. There were several studies about them and even utilizing the Finite Element Method to predict the chips generated. However, there were very few focusing on the effect of chips formation to working safety. This safety topic is important because of the trend of manufacturing process toward lean manufacturing. The principal is 5S which include s: sort, set in order, shine, standardize and sustain. In this study, it will present the type and size of chips recommended for working safety by changing the cutting parameter. The target chip shape is discontinuous, so cutting parameters to improve the process is the depth of cut 2 mm and feed rate range from 0,1 to 0,2 mm/rev.