Chip thickness progression in milling modes In which milling mode does the instantaneous chip thickness start at a minimum (near zero) at entry and increase to a maximum at exit of each tooth engagement?

Difficulty: Easy

Correct Answer: Conventional milling (up milling)

Explanation:


Introduction / Context:
The chip thickness profile during tooth engagement affects cutting forces, surface finish, and workholding loads. Understanding whether chip thickness increases or decreases through engagement helps select milling mode for stability and finish.



Given Data / Assumptions:

  • Standard cutter rotation and feed directions.
  • No significant runout or backlash compensation considered.
  • Rigid clamping is assumed.


Concept / Approach:
In conventional (up) milling, the cutter tooth starts cutting at near zero chip thickness and leaves at maximum thickness; the force tends to lift the work. In climb (down) milling, the tooth begins at maximum thickness and finishes at zero, tending to press the work down and often improving finish with modern backlash-free drives.



Step-by-Step Solution:
Analyze the relative motion in up milling: chip grows from entry to exit.Relate to force direction: upward component in conventional milling.Therefore, the “minimum to maximum” progression corresponds to conventional (up) milling.



Verification / Alternative check:
Textbook chip-thickness diagrams confirm the opposite progression for climb milling.



Why Other Options Are Wrong:
Climb milling is the reverse (maximum to minimum). Face and end milling describe cutter geometry, not chip progression mode; direction still matters. High-speed milling does not change the fundamental kinematics.



Common Pitfalls:
Ignoring machine backlash that can make climb milling risky on older machines; assuming face milling always equals one mode—it depends on feed direction relative to rotation.



Final Answer:
Conventional milling (up milling)


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