Cutting Speeds & RPM Calculations

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Cutting Speeds & RPM Calculations

Tools used in drilling operations represent nearly 25% of all the tools being used in the world. There are
those operations that are strictly drilling operations, but we also use drilling machines to perform other
operations such as reaming, tapping, countersinking and counterboring. The rules and principles of
cutting speeds and RPM calculations apply to all of the operations being performed on drilling
machines. An example of this would be reaming. Reaming is done at half the speed and twice the feed
as drilling. This rule still applies on the drill press as it does on the milling machine or the lathe. Pay
very close attention to the information introduced in this unit and other units dealing with cutting speeds
because cutting speeds have the greatest impact on tool life.

Cutting Speed
Cutting speed is the speed at the outside edge of the tool as it is cutting. This is also known as surface
speed. Surface speed, surface footage, and surface area are all directly related. If two tools of different
sizes are turning at the same revolutions per minute (RPM), the larger tool has a greater surface speed.
Surface speed is measured in surface feet per minute (SFPM). All cutting tools work on the surface
footage principle. Cutting speeds depend primarily on the kind of material you are cutting and the kind
of cutting tool you are using. The hardness of the work material has a great deal to do with the
recommended cutting speed. The harder the work material, the slower the cutting speed. The softer the
work material, the faster the recommended cutting speed (Figure 1).

Increasing Cutting Speed

Figure 1
The hardness of the cutting tool material will also have a great deal to do with the recommended cutting
speed. The harder the drill, the faster the cutting speed (Figure 2). The softer the drill, the slower the
recommended cutting speed.

Increasing Cutting Speed

Figure 2
The three factors, cutting speed, feedrate and depth of cut, are known as cutting conditions. Cutting
conditions are determined by the machinability rating of the material. Machinability is the comparing of
materials on their ability to be machined. From machinability ratings we can derive recommended
cutting speeds. Recommended cutting speeds are given in charts. These charts can be found in the
Machinerys Handbook, textbook, or a chart given to you by your tool salesperson. In Table 3 you will
find a typical recommended cutting speed chart for drilling.

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Table 3 Recommended Cutting Speeds for Drilling with High-Speed Steel Drills
For reamers, use 1/2 to 2/3 speed given in this table.

Material

Plain Carbon Steels

AISI1019, 1020, 1030, 1040,
1050, 1060, 1070, 1080, 1090

Alloy Steels
AISI-1320, 2317, 2515,
3120, 3316, 4012, 4020,
4120, 4128, 4320, 4620,
4720, 4820, 5020, 5120,
6120, 6325, 6415, 8620,
8720, 9315
Alloy Steels
AISI-1330, 1340, 2330,
2340, 3130, 3140, 3150,
4030, 4063, 4130, 4140,
4150, 4340, 4640, 5130,
5140, 5160, 52100, 6150,
6180, 6240, 6290, 6340,
6380, 8640, 8660, 8740,
9260, 9445, 9840, 9850
Stainless Steels
Standard Grades
Austenitic
Annealed
Cold-Drawn
Ferritic
Martensitic
Annealed

Quenched & Tempered

Free Machining Grades
Austenitic
Annealed

Hardness,
Bhn

Cutting
Speed,
fpm

120-150
150170
170190
190220
220280
280350
350425

80120
7090
6080
5070
4050
3040
1530

125175
175225
225275
275325
325375
375425

6080
5070
4560
3555
3040
1530

175225
225275
275325
325375
375425

5070
4060
3050
2540
1530

Material

Stainless Steels (Cont.)

Cold-Drawn
Ferritic
Martensitic
Annealed
Cold-Drawn
Quenched & Tempered

Tool Steels
Water Hardening
Cold Work
Shock Resisting
Mold
High-Speed Steel

Hardness,
Bhn

Cutting
Speed,
fpm

225275
135185

6090
100120

135185
185240
275325
375425

100130
90120
5060
3040

150250
200250
175225
100150
150200
200250
250-275

7080
2040
4050
6070
5060
3040
1530

110140
150190
190220
220260
260320

90140
80100
6080
5070
3040

110160
160200
200240
240280

120140
90110
6090
5060

Gray Cast-Iron

Malleable Iron
Ferritic
Pearlitic

135185
225275
135185

4050
3040
5060

135175
175225
275325
375425

5570
5060
3040
1530

Aluminum Alloys
Cast-Nonheat Treated
Cast-Heat Treated
Wrought-Cold Drawn
Wrought-Heat Treated

200300
150250
150300
140300

Brass & Bronze (Ordinary)

150300
Bronze (High Strength)

135185

80100

30100

The spindle speed must be set so that the tool will be operating at the correct cutting speed. To set the proper spindle speed, we
need to calculate the proper revolution per minute or RPM setting. We stated earlier that cutting speed or surface speed would
change with the size of the tool. So to keep the surface speed the same for each size tool, we must use a formula, which includes
the size of the tool, to calculate the proper RPM to maintain the proper surface footage.

Calculating RPM for Drilling

Top

The RPM setting for drilling depends on the cutting speed of the material and the size of the drill bit. The RPM setting will
change with the size of the bit. As the drill bit gets smaller, the RPM must increase to maintain the recommended surface

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footage. Take the case of the wheel. Think of the drill bit as a wheel and the cutting speed as a distance. A larger wheel (drill bit)
will need to turn less revolutions to cover the same distance in the same amount of time than a smaller wheel (drill bit).
Therefore, to maintain the recommended cutting speed, larger drills must be run at slower speeds than smaller drills.
The drill press must be set so that the drill bit will be operating at the proper surface speed. Spindle speed settings on the drill
press are done in RPMs. To calculate the proper RPM for the tool, we must use the following formula:

This simplified version of the RPM formula is the most common formula used in machine shops. This RPM formula can be
used for other machining operations as well.
Let's put this formula to work in calculating the RPM for the drilling example below. Use the recommended cutting speed charts
in Table 3.
A 0.50 drill is being used to drill a piece of 1018 steel with a brinnel hardness of 200. Calculate the RPM setting to perform this
drilling operation.

Although you have calculated the RPM, remember that this is only a recommendation. Some judgment must be made in
selecting the actual R.P.M. setting to use. There are always outside factors that must go into deciding on the proper speed and
feed to use. Ask yourself these questions before deciding on an R.P.M. setting. How sturdy is my setup? Go slower for setups,
which lack a great deal of rigidity. Am I using coolant? You may be able to use a faster speed if you are using flood coolant.
How deep am I drilling? If youre drilling a deep hole, there is no place for the heat to go. You may have to slow the RPM down
for deep whole drilling.
The greatest indicator of proper and improper cutting speed is the color of the chip. When using a high-speed steel drill bit, the
chips should never be turning brown or blue. Straw-colored chips indicate that you are on the maximum edge of the cutting
speed for your cutting conditions. When using carbide, chip colors can range from amber to blue, but never black. A dark purple
color will indicate that you are on the maximum edge of your
cutting conditions. Carbide cutting tools are covered in much greater detail in another section of your learning materials.

Lets try some more examples.

A 1.00-inch, high-speed steel (HSS) drill is being used on a piece of 1045 steel with a brinnel hardness of 300. Calculate the
RPM setting to perform this cutting operation.

A 3/4-inch (HSS) drill is used on a piece of (leaded) 11L17 steel with a brinnel hardness of 100. Calculate the RPM setting to
perform this drilling operation.

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Calculating RPM for Reaming

The drill press RPM setting for reaming depends on the cutting speed of the material and the size of the ream. The RPM setting
will change with the size of the ream. As the ream gets smaller, the RPM must increase to maintain the recommended surface
footage. Although you will find specific cutting speeds for reaming, a simple rule of half the speed will work for most reaming
operations. Using half the spindle speed you calculated for the drilling operation is a commonly accepted method for
determining the reaming speed in most machine shops.

Lets try an example.

A high speed steel "G" drill is being used prior to reaming a 3/8 hole on a piece of 1095 steel with a brinnel hardness of 300.
Calculate the RPM setting to perform the drilling and reaming operations.

Half the speed for reaming would be = 432 / 2 = 216 RPM for reaming.
Calculating RPM for Countersinking and Counterboring

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The drill press RPM setting for countersinking and counterboring also depends on the cutting speed of the material and the size
of the tool. The RPM setting will change with the size of the tool. As the cutting tool gets smaller, the RPM must increase to
maintain the recommended surface footage. Although you will find specific cutting speeds for countersinking and
counterboring, a simple rule of 1/3 the speed of a drill of the same size will work for most countersinking and counterboring
operations. The RPM for a counterbore would be fairly simple to calculate using the 1/3 method, but calculating the RPM for a
countersink brings about a different set of circumstances. The countersink is tapered (Figure 4).

Figure 4

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As you can see from the figure, the RPM setting

would be slower for a countersink being cut at
diameter "B," than for a countersink being cut at
diameter "A".

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Cutting Speeds & RPM Calculations

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The part prints will usually state the

finished diameter of the countersink
(Figure 5). Use this as the diameter for
calculating the spindle speed setting.
Otherwise, use an approximate size
and watch your chip color carefully.

Figure 5

Lets try an example.

Lets calculate the RPM for the countersink in Figure 5. The material is 1045 steel with a brinnel hardness (bhn) of 200.

One-third the speed for countersinking would be = 789/ 3 = 263 RPM.

Center Drill RPM Calculations
A center drill or combination drill and countersink (Figure 6) is used for spotting holes in workpieces or for making center holes
for turning work. Center drills, as you can see from the illustration, are short and sturdy and will not bend or flex under pressure.
When calculating the proper RPM for using a center drill, use the diameter of the pilot for your calculations. Center drills will
break if they are run too slowly. Using the smaller diameter of the center drill will assure that the RPM setting is sufficient. If
you find that the drill chatters as you reach the proper depth, slightly decrease the RPM setting.

Figure 6

Lets try an example.

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Lets calculate the RPM for the center drilling 1018 steel with brinnel hardness (bhn) of 100. A #4 center drill with a pilot drill
diameter of 1/8 inch will be used.

RPM Calculation for Threading

Top

Selecting the best RPM for power tapping can be very complicated. There are many variables that must be taken into
consideration when selecting the best spindle speed for machine tapping. Among the variables are:
A. Material to be tapped. Cutting speeds need to decrease with the hardness of the material.
B. Length of the hole. The deeper the hole the slower the RPM.
C. Size of the chamfer on the tap. Taps with long chamfer tapping short holes can be run faster. However, taps with long
chamfers tapping long holes must be run slower.
D. Pitch of the thread. Coarse taps need to be run slower than fine taps.
E. Percentage of full thread. The higher the percentage of full threads the slower the RPM.
F. Type and amount of cutting fluid. The greater the amount of cutting fluid getting to the tap the faster the RPM.
G. Surface treatment of the tap. A tap that has been nitride or oxide coated can be run much faster than a tap, with no
coating.
H. Type of tap. Spiral-fluted and spiral-pointed taps can operate at higher cutting speeds than can straight-fluted taps.
The RPM formula for tapping is no different from the other formula we have been using, but the consideration mentioned for
tapping must be made before we actually do any power tapping. Until you know how the tap will operate under your conditions,
start with 1/3 to 1/2 the calculated RPM and gradually increase the RPM to the capacity of the conditions. A table of
recommended cutting speeds for threading is included in Table 7.
Table 7 Cutting Speeds for Machine Tapping

Material

Low Carbon Steels

Up to .25% C
Medium Carbon Steels
.30 to .60% C
Annealed
Heat Treated
(220 to 280 Bhn)

Cutting
Speed, fpm

40 to 80

Material

Cutting
Speed, fpm

Aluminum

50 to 200

Brass

50 to 200

Manganese Bronze

30 to 60

30 to 60

Phosphor Bronze

20 to 50

Naval Brass

30 to 60
80 to 100

20 to 40

Stainless Steels

5 to 35

Gray Cast-Iron

40 to 100

Malleable Iron
Ferritic
Pearlitic

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Monel Metal

Tool Steels, High Carbon

and High-Speed Steel

80 to 120
40 to 80

Tobin Bronze
Plastics
Thermoplastics
Thermosetting
Hard Rubber

20 to 40
80 to 100

50 to 100
50 to 100
50 to 100

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Bakelite
60 to 150

Zinc Die Castings

50 to 100

Lets try an example.

Lets calculate the RPM for tapping a 1/2-13 UNC hole. The material is 1018 steel with a brinnel hardness (bhn) of 100.

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