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<p>Chips are an important factor affecting tool life and the surface quality of threads. During thread machining, taps operate in a semi-enclosed space, making it difficult to observe chip breaking and evacuation. In this study, 45# steel was used as the workpiece material to investigate the chips generated during machining. First, the chip morphology was analyzed based on finite element experiments to determine the machining conditions. Then, scanning electron microscopy was used to observe the fracture surfaces of selected chips, ultimately determining their fracture mechanism. By designing different machining parameters, the study found that as spindle speed increased, the chips gradually changed from ductile fracture to brittle fracture; an appropriate cutting tap angle favored chip breaking; in terms of cutting force, suitable machining parameters reduced the maximum cutting force by 43.75 %; and the cutting temperature decreased by 6.65 %.</p>

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The influence of chip fracture morphology on chip removal efficiency in deep hole thread machining

  • 期刊论文

  • 发表日期：

    2026年5月12日

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  • Minli Zheng,
  • Zongwei Liu,
  • Wei Zhang

摘要

Chips are an important factor affecting tool life and the surface quality of threads. During thread machining, taps operate in a semi-enclosed space, making it difficult to observe chip breaking and evacuation. In this study, 45# steel was used as the workpiece material to investigate the chips generated during machining. First, the chip morphology was analyzed based on finite element experiments to determine the machining conditions. Then, scanning electron microscopy was used to observe the fracture surfaces of selected chips, ultimately determining their fracture mechanism. By designing different machining parameters, the study found that as spindle speed increased, the chips gradually changed from ductile fracture to brittle fracture; an appropriate cutting tap angle favored chip breaking; in terms of cutting force, suitable machining parameters reduced the maximum cutting force by 43.75 %; and the cutting temperature decreased by 6.65 %.