Chip formation and chip evacuation are critical issues in boring operations,
especially in blind holes. Inappropriate cutting data can lead to too short/thick chips and excessive cutting forces, resulting in deflection and vibration. Long chips can accumulate in the hole and cause surface finish deterioration and chip jamming, leading to insert breakdown.
Ideal chips should be in the form of defined commas or spirals that are easily evacuated from the hole. Factors that have an influence on chip breaking are:
- the insert micro- and macrogeometry
- cutting depth, feed and cutting speed
- nose radius
- lead angle.