Three-dimensional characterization of abrasive chips using micro-computed tomography

Chip formation is considered one important indicator to evaluate machining processes. In particular, geometric features of chips may provide important insights for the assessment of machining stability and productivity. In fixed-abrasive machining processes, such as grinding and honing, chips are simultaneously produced by many of the geometrically undefined cutting edges. Despite being “undefined,” geometric features of abrasive grains can still be statistically characterized or described. Accordingly, it can be assumed that, under stable machining conditions, the geometric features of abrasive chips may also conform to certain statistical patterns. However, statistical characterization of abrasive chips can be very challenging due to their large quantity, irregular shapes, minuscule size, and sometimes tangled condition. In this study, an analysis method combining metallographic preparation and micro-computed tomography (micro-CT) has been developed to characterize abrasive chips produced by a honing stone. The results regarding the geometric characteristics of the obtained massive abrasive chips, i.e., their sizes and shapes, were presented and statistically described. It was found most chips had a size around 50 µm and the shape being a slightly elongated and curved cone. Most of the geometric features could meet a positive skewness distribution.