Quantitative analysis of chip segmentation in machining using an automated image processing method

Abstract

Analysis of chip formation is one of the most established and informative methods for description of the cutting process. A number of established techniques ranging from optical to electron microscopy have been developed for analysis of continuous chips. Yet, machining of difficult-to-cut materials is accompanied by segmented chip formation. This paper presents an original algorithm based on image processing of segmented chips that quantifies chip compression ratio, dimensions of segments, segmentation frequency, etc. The algorithm was validated when analyzing chip cross-sections for the cases of orthogonal turning of stainless steel 316L and Inconel 718.