The chips generated during up milling and down milling of pine wood by helical router-bits
Development of new helical edge router bits (helix angle 15°, 30°, 45°, and 60°) with a cutting circle diameter of 8 mm was studied. The purpose of the research work was to investigate chips formation and surface roughness characteristics in milling the pine wood by the straight and helical edge bits. The generated chips were classified in four types by sieving into spiral chip (5 mesh), flow chip (10 mesh), thin chip (30 mesh), and granule chip (< 30 mesh). The experimental results showed that the spiral chip was generated most often (on a weight percentage basis) by the bits during down milling process. More flow and thin chips were produced by the bits during up milling process. Better surface roughness was produced by bits during down milling compared to up milling. When the helix angle of the bits increased the amount of spiral and flow chips were increased and granule chip was reduced. The machined surface was better in roughness (lower Ra values) as the helix angle of the bits increased both in up milling and down milling processes.