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Cutting Data (Updated)

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Dilshan Sampath
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16 views

Cutting Data (Updated)

Uploaded by

Dilshan Sampath
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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SOLID MOTIONS

Cutting Data
Tables on the following pages provide basic speed, feed and cutting data for some
of the materials commonly used for prototypes. Use the tool manufacturer’s data
instead whenever it is available

Tip: Never use tools that have been used to machine metal to cut plastic. The sharp
edge of the tool will be compromised and cutting performance and finish will suffer.
A good practice is to keep two sets of tools: one for plastic and one for metal.
Tip: High speed steel cutters work best for plastics. Carbide cutters work better for
aluminum and other metals.
SOLID MOTIONS

Feeding Data

Speed Formula
Milling machine cutting speeds are derived from the following formula:

Speed is the rotational frequency of the tool (Spindle Speed) in revolutions per minute (RPM).

SFM (Surface Feet per Minute) is the speed at which the material moves past the cutting edge (outside
diameter) of the tool in feet per minute. SFM values depend on the tool type, tool material, and material
being machined.

Circumference is the circumference of the cutting tool in feet.

How Speed Formula is Derived

Because cutting tools are defined by their diameter in inches, this formula is rewritten and simplified as
follows:
SOLID MOTIONS

DIA is the tool diameter in inches.

3.82 is a constant derived from 12/π which converts the tool circumference in feet to diameter in inches.

Feed Formula
Cutting feeds are in (IPM) and use the following formula

Feed is the linear feed of the tool through the material in inches per minute.

Speed is the result of the speed formula (Figure 15) in revolutions per minute.

CL is the chip load, or how much material each cutting edge of the tool removes per revolution. Chip
load is sometimes referred to as feed per tooth (FPT) or inches per rev (IPR).

Num Flutes is the number of cutting flutes. (For a twist drill, this value is one.
SOLID MOTIONS

Tap Feed Formula


For tapping operations, feed rate is based on the number of threads per inch and feed rate:

Feed is the linear feed of the tool through the material in inches per minute.

Speed is the result of the previous formula in revolutions per minute.

TPI is the threads per inch of the tap. For example, the TPI of a ¼-20 tap is 20
SOLID MOTIONS

CHIP LOAD: CALCULATOR, FORMULAS, AND


CHARTS
The term Chip load (also called Maximum Chip Thickness), can be
confusing since it has two different meanings that are commonly used.
Meaning #1 – How Chip load is used in milling catalogs, and by most machinists.

The maximum load that the cutting edge of a specific milling cutter
(or indexable insert) can withstand without yielding or having a very
short tool-life.

The chip load is specified in mm/tooth or Inch per tooth (IPT) units.
This property is so helpful because it depends only on the geometry of
the cutting edge and the type of workpiece material. It is independent
of application conditions such as speed or depth of cut. It is convenient for
both the tool suppliers and the users.

• For the cutting tool suppliers, it enables them to list the


recommended feedrates in one chart, independent of the application
conditions.
• The CNC programmers can input the chip load value from the cutting tool
supplier into the CAD/CAM software, and the software calculates the
correct table feed accordingly.
• Once the end-user figures out a chip load that works well for a cutter and
material combination, they can use this number confidently in many other
applications by calculating the table feed based on the known chip load each
time.
SOLID MOTIONS

Meaning #2 – The physical meaning of Chip Load


The maximum width of the chip that the tooth (or indexable inserts) of a
milling cutter cuts out of the material in one spindle rotation.

• The chip load equals exactly the feed per tooth (Fz) when the radial
depth of cut (Ae) is greater or equal to the cutter radius. As Ae
becomes smaller, the chip load also becomes smaller. Some people
refer to the Fz as if it is the chip load. This is a mistake since it is not
true in all conditions!
• The width of the chip is largest at the point of entry and gradually
gets smaller until it is zero at the point of exit. The chip load is the
maximum value. A related term is Average Chip thickness which is
used for force and power calculations.

•
SOLID MOTIONS

Getting Cutting Data From Chip Load

To calculate the Milling Feed rate, you will need first


to prepare the following basic data:
1. Chip Load [CL] – What you obtained from this calculator.
2. Cutter Shape [90°, Ball nose, Chamfering, Round, etc]
3. Cutter Diameter [D] – If you are using a shaped cutter (Non 90°),
you should use the Effective Cutter Diameter.
4. Number of Teeth [Z]
The user always knows the above three.

4. Radial Depth of Cut [Ae] – Depends on how you plan to perform


your application.
5. Cutting Speed [Vc] – Get wit with our Speeds and Feeds
Calculator or from the tool supplier’s catalog/website
SOLID MOTIONS

With the above parameters, you can proceed to


calculate the Milling Feed (Table Feed)

1. Calculate the Chip Thinning factors in order to get the Feed per Tooth.
The Chip Thinning factors ensure that the actual Feed per Tooth [Fz}
will maintain the desired Chip Load according to the tool geometry
and application settings.
2. Radial Chip Thinning Factor [RCTF] –
The radial chip thinning factor should be implemented with the Radial
Depth of Cut [Ae] being smaller than the cutter’s radius. (When Ae is
bigger, the factor is 1). At very small Ae, the factor can be up to 3 times!

Speed Feed Calculators


SOLID MOTIONS

Best Practice Machining Parameters


SOLID MOTIONS

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