SECTION 2.1
Chip Formation

Chip formation involves three basic requirements: (1) the cutting tool must be harder than the part material, (2) there must be interference between the tool and the part as designated by the feed rate and cut per tooth, and (3) there must be a relative motion or cutting velocity between the tool and workpiece with sufficient force to overcome the resistance of the part material.

As long as these three conditions exist, the portion of the material being machined that interferes with the free passage of the tool will be displaced to create a chip. Many combinations exist that may fulfill such requirements. Variations in tool material and tool geometry, feed and depth of cut, cutting velocity, and part material have an effect not only upon the formation of the chip, but also upon cutting force, cutting horsepower, cutting temperatures, tool wear and tool life, dimensional stability, and the quality of the newly created surface.