Chip type when machining mild steel During turning of mild steel under normal conditions (adequate rake and speed), what type of chip is most commonly produced?

Introduction / Context:
Chip morphology depends on material ductility, cutting speed, rake, and lubrication. Recognizing typical chip forms helps diagnose cutting issues and choose chip control features.

Given Data / Assumptions:

• Work material: mild steel (ductile).
• Tool: standard positive rake HSS/carbide.
• Cutting speed and feed are within normal ranges with coolant.

Concept / Approach:
Ductile materials like mild steel usually produce continuous chips due to stable plastic flow ahead of the tool. Depending on speed and lubrication, a built-up edge may form intermittently, but the underlying chip type remains continuous. Discontinuous chips are typical of brittle materials or very low speeds/large feeds. Segmented adiabatic shear chips occur at very high speeds in difficult alloys.

Step-by-Step Solution:

Verification / Alternative check:
Textbook chip classification and shop observations consistently show continuous chips for steels of low to medium carbon when tooling and speeds are appropriate.

Why Other Options Are Wrong:
Discontinuous chips: associated with brittle materials or extreme conditions.Continuous with BUE only: BUE may occur, but the chip type is still continuous; the option over-specifies.Segmented adiabatic shear: typical in high-speed machining of titanium/nickel alloys.No chip: not applicable to conventional cutting.

Common Pitfalls:
Confusing presence of BUE with discontinuous chips; BUE is an interface phenomenon, not a chip-class change.

Final Answer:

Continuous