2020/10/21 Milling formulas and definitions

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Milling formulas and de nitions

Here you nd a collection of good to have milling formulas and de nitions that are
used when it comes to the milling process, milling cutters, milling techniques and
more. Knowing how to calculate correct cutting speed, feed per tooth or metal
removal rate is crucial for good results in any milling operation.

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Metric Imperial

Table feed, vf  (mm/min) Table feed, vf  (inch/min)

Cutting speed, vc  (m/min) Cutting speed, vc  (ft/min)

Spindle speed, n  (r/min) Spindle speed, n  (rpm)

Feed per tooth, fz (mm) Feed per tooth, fz (inch)

Feed per revolution, fn (mm/rev) Feed per revolution, fn (inch/rev)

Metal removal rate, Q (cm3/min) Metal removal rate, Q (inch3/min)

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Net power, Pc (kW) Net power, Pc (HP)

Torque, Mc (Nm) Torque, Mc (lbf ft)

 
Symbol Designation/de nition Metric Imperial
ae Radial depth of cut mm inch
ap Axial depth of cut mm inch
DCap Cutting diameter at cutting depth ap mm inch
Dm Machined diameter (component diameter) mm inch
fz Feed per tooth mm inch
fn Feed per revolution mm/r inch
n Spindle speed rpm rpm
vc Cutting speed m/min ft/min
ve E ective cutting speed mm/min inch/min
vf Table feed mm/min inch/min
zc Number of e ective teeth pcs pcs
hex Maximum chip thickness mm inch
hm Average chip thickness mm inch
kc Speci c cutting force N/mm2 N/inch2
Pc Net power kW HP
Mc Torque Nm lbf ft
Q Metal removal rate cm3/min inch3/min
KAPR Entering angle degree
PSIR Lead angle degree
BD Body diameter mm inch
DC Cutting diameter mm inch
LU Usable length mm inch
 

The milling process – de nitions

Cutting speed,vc
Indicates the surface speed at which the cutting edge machines the workpiece.

E ective or true cutting speed, ve

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Indicates the surface speed at the e ective diameter (DCap). This value is necessary for determining the true cutting data at the
actual depth of cut (ap). This is a particularly important value when using round insert cutters, ball nose end mills and all cutters
with larger corner radii, as well as cutters with an entering angle smaller than 90 degrees.

Spindle speed, n
The number of revolutions the milling tool makes per minute on the spindle. This is a machine oriented value, which is calculated
from the recommended cutting speed value for an operation.

Feed per tooth, fz

A value for calculating the table feed. The feed per tooth value is calculated from the recommended maximum chip thickness
value.

Feed per revolution, fn

Auxiliary value indicating how far the tool moves during one complete rotation. It is used speci cally for feed calculations and
often to determine the nishing capability of a cutter.

Feed per minute, vf

Also known as the table feed, machine feed or feed speed. It is the feed of the tool in relation to the workpiece in distance per
time-unit related to feed per tooth and number of teeth in the cutter. The number of available cutter teeth in the tool (zn) varies
considerably and is used to determine the table feed while the e ective number of teeth (zc) is the number of e ective teeth in
cut. Feed per revolution (fn) in mm/rev (inch/rev) is a value used speci cally for feed calculations and often to determine the
nishing capability of a cutter.

Maximum chip thickness, hex

This value is a result of the cutter engagement as it is related to (fz), (ae) and (kr). The chip thickness is an important
consideration when deciding the feed per tooth, to ensure that the most productive table feed is employed.

Average chip thickness, hm

A useful value in determining the speci c cutting force, used for net power calculations.
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Metal removal rate, Q  (cm3/min)

The volume of metal removed in cubic mm per minute (inch3/minute). It is established using the values for cutting depth, width
and feed.

Speci c cutting force, kct

A material constant which is a factor used for power calculations, expressed in N/mm2

Machining time, Tc  (min)

Machining length (lm) divided by the table feed (vf).

Net power, Pc and e ciency, ηmt

Machine tool oriented values, which assist in calculating the net power to ensure that the machine can handle the cutter and
operation.

Milling techniques – de nitions

Linear ramping
A simultaneous straight movement in axial and radial feed directions.

Circular milling
A circular tool path on a constant z-level (circular interpolation).

Circular ramping
A circular ramping tool path (helical interpolation).

Waterline milling
Milling on a constant z-level.

Point milling
A shallow radial cut with round insert or ball nose cutters in which the cutting zone is moved away from the tool centre.

Scallop
A con guration with cusps that occurs when producing sculptured surfaces.

Speci c milling cutter formulas

Formulas for milling cutters having a straight cutting edge
 
 

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Max. cutting diameter at a speci c depth (mm).

 
Face milling (centred workpiece), straight edge and side milling (ae > Dcap/2) mm

 
Side milling (ae < Dcap/2) straight edge mm.

Formulas for milling cutters with round inserts

 
Max. cutting diameter at a speci c depth (mm).  

 
Face milling round insert (ae > Dcap/2) (mm)

 
Side milling (ae < Dcap/2) and round insert (ap < iC/2) mm.

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Ball nose end mills

 
Max. cutting diameter at a speci c depth (mm). 

 
Feed per tooth (mm/tooth), cutter centered.

 
Feed per tooth (mm/tooth), side milling

Internal circular ramping (3-axes) or circular milling (2-axes)

Calculated version
 
Peripheral feed (mm/min) Tool centre feed (mm/min)  

Radial depth of cut (mm)

In a solid workpiece where Dw = 0 and ae e = Dm/2

Feed per tooth (mm)

When widening a hole,

Feed per tooth (mm)  

 
 

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Circular ramping in solid workpiece Circular ramping or circular milling to widen a hole.

Circular milling with a roll into cut tool path, Dvf1

 

Formulas for external circular ramping (3-axes) or circular milling (2-axes)

Calculated version
 
 

Peripheral feed (mm/min)

Tool centre feed (mm/min)

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Feed per tooth (mm)

Milling insert de nitions

Insert geometry
A closer study of the cutting edge geometry reveals two important angles on the insert:

rake angle (γ)

cutting edge angle (β)

The macro geometry is developed for work under light, medium or heavy conditions.

L (Light) geometry has a more positive, but weaker edge (large γ, small β)

H (Heavy) geometry has a stronger, but less positive edge (small γ, large β)

The macro geometry a ects many parameters in the cutting process. An insert with a strong cutting edge can work at higher
loads, but also generates higher cutting forces, consumes more power and generates more heat. Material optimized geometries
are designated with the ISO classi cation letter. For example, geometries for cast iron: -KL, -KM and -KH.

 
 
Geometry
Parameter L M H
Edge strength
Cutting forces
Power consumption Low Medium High
Max. chip thickness
Heat generated
 

Insert corner design

The most important part of the cutting edge for producing the surface is the parallel land bs1 or, when applicable, a convex
wiper land bs2, or corner radius, rε.

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Corner radius, r Parallel land (bs1) Wiper land (bs2)

Milling cutter de nitions

Entering angle, (kr) (degrees)
The major cutting edge angle (kr) of the cutter is the dominant factor as it a ects the cutting force direction
and the chip thickness.
 
 

Cutter diameter – Dc (mm)

The cutter diameter (Dc) is measured over the point (PK), where the
main cutting edge meets the parallel land.

The most important diameter to consider is (Dcap) – the e ective

cutting diameter at the actual depth of cut (ap) – used for calculation of
the true cutting speed. D3 is the largest diameter of the insert, for
some cutters it is equal to Dc.

 
Cutting depth – ap (mm)
The cutting depth (ap) is the di erence between the uncut and the cut
surface in axial direction. Maximum ap is primarily limited by the insert
size and machine power.

Another critical factor in roughing operations is torque, and in nishing

operations, it is vibration.

Cutting width, ae (mm)

The radial width of the cutter (ae) engaged in cut. Especially critical in plunging step over, and for vibration in corner milling, where
maximum ae is especially critical.

Radial immersion, ae/Dc

Radial immersion (ae / Dc) is the width of the cut in relation to the diameter of the cutter.

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Number of e ective cutting edges on the tool, zc

For determining the table feed (vf) and the productivity. This often has a critical in uence on chip evacuation and operational
stability.

The total number of cutting edges on the tool, zn

 

Distance between the e ective cutting edges, u

For a speci c milling cutter diameter, you can choose between di erent pitches: coarse (-L), close (-M), extra close (- H). An X
added to the code, denotes a cutter version whose pitch is slightly closer than its basic design.

Di erential pitch
Indicates an unequal space between the teeth on a cutter. This is a very e ective way to minimize vibration tendencies.

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