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Explaining the term 'chip load' --what it means, and why it matters. June 19, 2005Monte Carlo 12.5g 3 Tone Holographic Poker Chips (25/Pkg) $4.85. 13.5 Gram Yin Yang Poker Chips (25/Pkg) $2.69. 7.5 Gram Showgirl Poker Chips (25/Pkg) $0.99 $1.75. Switch to the dark mode that's kinder on your eyes at night time. Switch to the light mode that's kinder on your eyes at day time. The Chip Cave has the largest selection of clay-composite, ceramic, and plastic poker chips around. It’s as if you’re a kid in a candy store, where the candy is replaced with poker chips. I know, it doesn’t get much better than this.
Question
I was wondering about what chip load is. The value supplied by tool manufacturers for each tool has a particular chip load. For example a two-flute up/down 1/2' diameter compression bit has a recommended chip load of .024-.026 for (chip board) from Onsrud. Does this value represent the amount in inches that the tool removes for each revolution of the tool?
Forum Responses
(CNC Forum)
From contributor G:
The chip load refers to the size of the chip material after it has been machined.
From contributor M:
You can determine your chip load or figure your speeds and rpm to target the proper chip load with the following formulae.
Chip load = Feed rate / (RPM * # of Cutting Edges)
Feed rate = RPM * Cutting Edges * Chip load
RPM = Feed rate / (# of cutting edges * Chip load)
From contributor K:
As you can see from the formulae, chip load can help you to easily determine what your feed rate should be:
RPM=16,000
Flutes=3
Chip load=.020in/Rev, which means a feedrate of 16,000*3*.020=960 i.p.m.
This is a good starting point, but there are also a couple of other considerations. First, chip loading is ultimately a measure of how much heat is taken away from the cut and consequently from the cutting tool. Too little will cause the tool to overheat and die prematurely. Of course too much will put too great a load on the tool and spindle and give a poor quality of cut.
Other factors contributing to heat buildup must also be considered. One is plunging versus ramping into a cut. Plunging creates a tremendous amount of heat and will quickly kill a tool that has the proper feed rate.
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The other is deceleration at corners. If you are cutting a few large parts from a board, then the heat buildup as the spindle slows and/or stops when turning a corner will not be a big factor. But if you are cutting many smaller parts, this becomes a major factor. Also, with short movements at feed speed, the tool spends a lot of time at less than optimal feed rates, thus more heat buildup due to smaller chip loads.
The bottom line is that we never run our router at the maximum feed rate and RPM. We back off to about 60% (we are pretty conservative) so that the average chip load does not get too small.
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You will find that clay chips stack better than composite poker chips, beacause they are less slippery. The chips with graphics have a label inlay on them. These label inlays are recessed into the face of the chip, unlike ceramic poker chips, which the graphics are part of the chip.
All clay poker chips have some percentage of composite materials in them. The composite materials give the chip strength. A 100% pure clay chip would be extremely brittle and easy to break. Even our casino grade poker chips which have a higher percentage of clay can be broken in half, if you try to break them.
Generally, the more expensive a clay chip costs, the higher the percentage of clay it is made with. It is more complex to manufacturer chips with a higher clay content.
Weight has nothing to do with quality. Our highest quality chips are the 10 gram chips. The weight of a chip is is purely personal preference. Our most popular chips are the heavier 14 gram clay chips.
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All clay chips that weigh more than 11.5 grams have a metal insert in them to give them their weight. The larger the weight the heavier the chip.
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All of our clay chips are either 39mm or 40mm in diameter. The thickness of most of the chips are the same too.