The word "shavings" is the most common concept for the Russian language. But the types of shavings in the understanding of people are different. Some even attribute to the shrew instructive meaning. After all, they say about a strict boss that he removes shavings from his subordinates. At the same time, they mean that he is reporting employees for improper actions, an improper attitude to work, and is trying to eradicate vicious practices.
Something similar happens in the manufacture of parts: an extra layer is removed from the workpiece to obtain the necessary product. And shavings, they are shavings, are common production scrap. It is collected and sent for processing.
What is shavings?
Chip is a medium-sized fraction of any material, including wood, plastic, metal, which is a narrow filigree layer removed from the workpiece using planing equipment, knives or other tools. In metal production, shavings are a by-product. Her waste is expected. Unnecessary scraps of non-ferrous, ferrous and even precious metals are formed as a result of machining on drilling, milling and turning machines. As a rule, the structure of the chip remains identical with the regulated material of the product. In exceptional cases, a mixture of alloys that differ in chemical composition is found. This is possible after welding, soldering and similar manipulations.
Types of Chips
The metal cutting process (OMR) is carried out at specified parameters using tools and materials with different properties. Depending on this, forces arise in the cutting zone that affect the quality of processing and the formation of chips. Professor I.A. Thieme identified the following main types of chips:
- chipping chips - characteristic of cast iron processing, consisting of small fragments of grains;
- drainage chips - smooth, curled, most often formed during the processing of copper;
- chips of chipping (chipping) - fragments of material remaining from metal processing of hard steels and pobedit.
By the type and color of the chips, one can judge the quality of the surface obtained as a result of the OMR and the manufacturability of the process as a whole.
Turning parts
The most common OMR technique, allowing you to get the part of the desired configuration and roughness, is turning. The bottom line is to cut off an unwanted metal layer from a blank or blank. Acting on the removed layer with the front surface, the cutter deforms it. As a result of metal compression, the squeezed metal element is chipped off and is deployed with the front surface of the tool up. Next, the algorithm repeats: the chips are chipped, separated and curled into beautiful springs.
What kind of shavings are not encountered during turning? The following factors influence:
- the degree of cohesion of metal elements that are successively chipped during processing (drainage chips, breaks and chipping);
- cutting modes: spindle speed, caliper feed rate, cutting depth;
- the use of cutting fluids.
Chip color
In mechanical engineering, in particular metal cutting, there is such a thing as a discoloration color. It can be compared, for example, with iridescent stains of gasoline on the surface of a puddle after heavy rain. It turns out that knowledgeable machine tools can easily determine the degree of heating in the cutting zone and understand that something went wrong by the color of the pimple and the unusual appearance of the chip, and it is possible that a cutter that needs to be sharpened or replaced has become dull.
The nature of this phenomenon on the surface of a hot metal consists in the formation of the thinnest layer - a film of the color of discolouration. What is the degree of glow of the chips, such is the color of the film. The color gamut ranges from a slightly yellow hue at 200 0 , bypassing purple and dark blue at 270-290 ℃, to light gray, almost white at 400 0 .
Creative shavings
With genuine interest, students of engineering schools, who first came to the workshop for practice, admire fresh shavings. Snakes, beads, rings, nests - which enthusiastic young people can’t see in ordinary shavings.
Different shapes, colors and intricacies of shavings inspire some people to be creative. For example, one of them took a lot of photo frames with beautiful metal shavings and called the unusual gallery “Shavings, you space!”. Another author, Vladimir Kargin, a lover of creating three-dimensional panels, made a series of paintings made from various types of shavings. All themes of his paintings are related to nature.
Byproduct of production
Waste of all types of metal shavings, including non-ferrous, is disposed of and sent for recycling. This process is time-consuming: it includes chip sorting, oil extraction, crushing, briquetting and transportation for re-melting. Briquetting is necessary to minimize fumes during the remelting of chips in furnaces. The mechanisms used for processing chips:
- centrifuge for oil extraction;
- crusher for grinding chips;
- briquetting (baling) presses for compacting ramming chips.
All machine-tool workers know that when machining metals, you need to protect your eyes and hands: work with glasses or with protective shields installed on the machines, and remove the coiled and stuck shavings with a hook. Shavings often have a beautiful appearance, but it is always dangerous, because it happens: sharp, hot, prickly. Take care of yourself.