1040 SPEEDS AND FEEDS Planing Time. — The approximate time required to plane a surface can be deter- mined from the following formula in which T = time in minutes, L = length of stroke in feet, V_ = cutting speed in feet per minute, V, = return speed in feet per minute; W = ‘width of surface to be planed in inches, F = feed in inches, and 0.025 = approximate reversal time factor per stroke in minutes for most planets: wf 1 ro Mfrx(b+3) +005] Speeds for Metal-Cutting Saws. — The following speeds and feeds for solid-tooth, high-speed-steel, circular, metal-cutting saws are recommended by Saws International, Ine. (Sipm = surface feet per minute = 3.142 X blade diameter in inches * rpm of ‘saw shaft + 12). ‘Speeds, Feeds, and Tooth Angles for Sawing Various Materials P| °o | seomgees A Front | Back Rake | Rake ise (ae Stock Diameters (inches) Materials (ee) | dee [im wets | Wea | ahah = 24 | 12 | 6300sfm | Gzoostpm | 6000 sfpm | 5000 sfpm oar eo infmin_| 8s in/min | Soinimin | “75 infmin ight Allys | 22 | 10 | a600sfpm | 5300 afpm | 3000 sfpm | 2600 sfpm with Ca, yoinmin | G5inimin | €3in/min | 60 in/min Mg, and Zn Tight Alls [20 | 8 | 630sipm | Soosfpm | ssoatpm | 50 cpm ‘with High Si xGininin_ | r6infmin | i¢inimin | 12 infmin 20 | 10 | i300sfpm | 1150 sfpm | 1000 sfpm | 800 sfom en 2ginfmin | 2ginimin | 22 nmin | 23 in/min =e 15 | 8 | Woosipm | sisosfpm | 1000sfpm | Goo sfpm a4infmin| 2¢in/min | 22 infmin | 20 infin ro | § | soostpm | 360spm | a25sfpm | 300 sipm ae Ss inimin | Ginmin | Ss ifmin | 32 inlmin Zab | © | & | 2000sfm | 20008fpm | 1800 sfpm | 1800 sfpm eee ‘43 in/min | 43 inimin | 39 infin | 35 inimin BY] 8 [Baste [assim [ze stm | 66sfpm Sy Co be infin | sivmin | 3.5infmin | 3 inimin 2 | [ s60sipm | tsosfpm | isosfom {190 fpm ears 63inmin | 59in/nin | s5inimin | 5.2 min Medium Hard | 18 | 8 | toosfpm | toosfpm | fostpm | fostpm Steel siinmin | 47 infmin | 43 inimin | 43 inhmin 15 | 8 | 66sipm | 66sfpm | Sosiom | 57 sfpm pataet 43inimin | 4infmin | sivma | 3.3 infin Sinks Seat | 5 | 8 | stom | 6sstpm | osm | 57am 2inimin | 17sinimin | 1.95 inmin | 1:3 infinMACHINING POWER 1041 Spoods for Turning Unusual Materials. — Slate, on account of ts pecoliacly strat. iied formation, i rather dificult to tra, bat if handled carefully, can be machined in an ordinary lathe. The cutting speed should be about the same as forcast iron. A sheet of fiber or pressed paper should be interposed between the chuck or steadyrest Jaws and the sate, to protect the later. Slate rolls most not be centered and nin on the tilstock. A satisfactory method of supporting a slate roll having journals at the ends is to bore a piece of ignum vitae to receive the turned end of the roll, and center itfor the talstock spindle. Rubber can be tumed at peripheral speed of 200 feet per minute, although itis such easier to grind it with an abrasive wheel that is porous and soft. For cutting a rubber rollin two, the ordinary parting tool should not be used, but a tool shaped ike a knife; such a tool severs the rubber without removing any material, Guia percha can be turned as easily as wood, but the tools must be sharp and a 00d soap-and-water lubricant used Copper ean be tucned easily at 200 feet per minute Lime-stone such as is used in the construction of pillars for balconies, etc., can be turned at 150 feet per minute, and the formation of ornamental contours is quite easy. Marble isa treacherous material to turn. It should be cut with 2 tool such as would be used for brass, but ata speed suitable forcast iron. It must be handled very carefully to prevent flaws in the surface. The foregoing speeds are for high-speed steel tools. Tools tipped with tungsten carbide are adapted for cutting various non-metallic products which cannot be ma- chined readily with steel tools, such as slate, marble, synthetic plastic material, etc In driling slate and marble, use fat dis; and for plastic materials, tongsten-carbide- tipped twist drills. Cutting speeds ranging from 75 0 150 feet per minute have been used for dling slate (without coolant) and a feed of 0.025 inch per revolution for drills % and 1 inch in diameter. Estimating Machining Power. — Knowledge of the power required to perform machining operations is useful when planning new machining operations, for optim- izing existing machining operations, and to develop specifications for new machine tools that are to be acquired. The available power on any machine tool places a limit ‘on the size of the cut that it can-take. When much metal must be removed from the ‘workpiece it is advisable to estimate the cutting conditions that will utilize the maxi- mum power on the machine. Many machining operations require only light cuts to be taken for which the machine obviously has ample power; inthis event, estimating the power required is a wasteful effort. Since conditions in different shops may vary and Tachine tools are not all designed alike, some variations between the estimated results and those obtained on the job are to be expected: however, by using the methods provided in this section a feasonable estimate of the power required can be made, which will suffice in most practical situations. ‘The measure of power in customary inch units is the horsepower; in SI metric units itis the kilowait, which is used for both mechanical and electrical power. The power required to cut'a material is dependent upon the rate at which the material is being cut and upon an experimentally determined power constant, X,, which is also called the unit horsepower, unit power, or specific power consumption. The power Constant is equal to the horsepower required to cut a material ata rate of one cubic inch per minute; in SI metric units the power constant is equal to the power in kilowatts required to cut a material at a rate of one cubic centimeter per second, or 1000 cubic millimeters per second (1 em*= 1000 mm. Difierent values of the power constant are required for inch and for metric units, which are related as follows: to obtain the SI metric power constant, multiply the inch power constant by 2.73; to obtain the inch power constant, divide the SI metric power constant by 2.73. Values of the power constant in Tables 23, 24, and 25 can be used for all machining opera- tions except drilling and grinding. Values given are for sharp tools.1042 MACHINING POWER Table23. Power Constants, K,,for Wrought Steels, Using Sharp Cutting Tools zm | & | & tari Barns | anch | stMec Namber | Use| “Wac Phin Gabon Sls sone | 6 | azn wens | | i fous | i | tas tei | ie | ae tone | ae | 233 tow | ib | ie tone | is | cat Pain Carbon Ste ms = 220-240 89 2.43 foe | | G8 sews | oe | 13 ogee us ole eS Sate 29 sess ut Fre Machining eo ABST 268, 105, 101g, 1286, 00¢7 20819, hs soba. 3 | ee > | st | ta ABS sap atc = | ue ah tat ee a |S ‘oy ers wee | oe | x tou | is | tome | le | artist sssinseesee, jf Tre | a | im torn ianganaseamaaws, jf Zee | | te +4827, 4820, $130, 5132. 5135. 5149. $145, 5150, 6228. eas a ae Stan tgp So Sea. eag.ep ge ae || ae pose | ge | ia bese | os | oa sess | rae | 2S owe | as | ns ime | & | ie toe | oe | ty none | fs | 1? atstenso agree. soo. 406.s10.065,060, |] Seow | fe | tar Beso. Sis. Ss. Bene tooo | ie | owe | | SS osm | me | Gas gose | os | So bese | | 25 wows | op | as owe | ib | tas pone | | i ISH sponge te East eel aie now | ss | i oe |S | SBMACHINING POWER 1043 Table 24. Power Constants, Kp, for Ferrous Cast Metals, ‘Using Sharp Cutting Tools soa] 5 Baal 5 Mateiat | Hartoos | ind | siiuie|] matesar | wanes | inde | st Mac nba’ | Uae | “vai unter | Unie | “Unis Too-rao | oat | a6 |] Nalco on Sere | oes |S | eee Paine tote | oat | toe Boe | oh | is my cotton |] Hots | S32 | at || weaine | | Sooaeo | 982 | 3% Home | oh | ie sean | ae | se S228 | om | tt Soa | oor | 28 rgo-rts | 062 | 169 © diesen {| Beas] oe] 38 wwerns| oye | on Beep | 8B |b toy cotiron] | 5-308 | 933 | S72 pete ese Ste | os | 2h ‘The valve of the power constant is essentially unaffected by the cutting speed, the depth of cut, and by the cutting tool material. Factors that do affect the value of the power constant and thereby the power required to cut a material include the hardness and microstructure of the work material, the feed rate, the rake angle of the cutting tool, and whether the cutting edge of the tool is sharp or dull. Values are given in the power constant tables for different material hardness levels, when- ever this information is available. Feed factors for the power constant are given in Table 26. All metal cutting tools wear but a worn cutting edge requires more ywer to cut than a sharp cutting cdge. Factors to provide for tool wear are givea In Table 27. In this table, the extra-heavy-duty category for milling and turni occurs only on operations where the tool is allowed fo wear more than a norm: amount before it is replaced, such as roll turning. The effect of the rake angle Usually can be disregarded. The rake angle for which most ofthe data in the power constant tables are given is positive 14 degrees. Only when the deviation from this angle is large is it necessary to make an adjustment. Using a rake angle that is more positive reduces the power required approximately 1 per cent per degree; using a rake angle that is more negative increases the power required; ‘Table 25. Power Constant, K,, for High-Temperature Alloys, Tool Steel, Stainless Steel, and Nonferrous Metals, Using Sharp Cutting Tools Smeal], Breet | & | teat ertsos| inh | nisie|] ast ‘faa nda} die ‘oon Utne eee dat ‘Sas Tiggeapeatae Rios = as [oo ee ae sg Jose] ag [fsonmeesne—([SEER|S2] St ic oo) 2 Bielek| 2% Sionsoy 35 128) 3 acpi ca ats oe| os Seeaey So [use| doo || Serer ond on] ior B |t2| 38 [oe i: = || te oe rere Bre) 3 tee oa] 2 Mae sto |iao| 338 |] Sef, a eee an Sn |an| te || a se] os: fe HF (t8| 3B ecm rd ost owe Met 2a || soem se 23 | semeun ae | ee fae Toast 8 | Soo ° 2B |) Sas ome 3 $5 [fresnel la esr1044 MACHINING POWER Table 26. Feed Factors, C, for Power Constants Tach Unite SUMcti Uae Feed Feed Feed ¢ a ¢ xt ¢ mt c oom | 097 002 ie eas | 097 eors | 096 eos | ie os | oa eos | ong 207 10 cao | ose oor | 92 om | as eas | oss oom | age om | ia os | 090 cos | ge as | as oss | oa easy | ane os | re om | oa bos | ose 20 | ios om | om aego | oss om 06 ep | 88 oo | a8 O35 rae om | og bass | fe oss | tot om | at pon oa | a7 ex | ie reo | one oars ooo | on 03 | os 10 | or “Turingin rev miliog ta Nootk planing and sbaping—inlnvoke:broacking in tooth, {Turing—mner- mln —mmtooth: planing and shapiag—amsroke brosching—mmvooth again approximately 1 percent per degree. Many indexable insert cutting toolsareformed ‘with an integral chip breaker or other cutting edge modifications, which have the effect, of reducing the power required to cut a material. The extent of this effect cannot be predicted without a test of each design, Cutting fuids will also usually reduce the power required, when operating in the lower range of cutting speeds. Again, the extent ofthis effect cannot be predicted because each cutting fluid exhibits its own characteristics. “The machine tool transmits the power from the driving motor to the workpiece, where itis used to cut the material. The effectiveness of this transmission is measured by the machine tool efficiency factor, E. Average values of this factor are given in Table 28. Formulas for calculating the metal removal rate, Q, for different machining operations are given in Table 29. These formulas are used together with others given below. The following formulas can be used with either customary inch or with ST metric units. K,COW @ KsCOW _ E power at the cutting tool; hp, or kW power at the motor; hp, or kW Ky = power constant (ee Tables 23, 24, and 25) @ = metal removal rate; in3/min, or ems (see Table 29) ‘Table 27. Tool Wear Factors, W “Type of Operation w or all operations with sharp cutting tools 100) ‘Turning: Finish turing light cuts) 110. ‘Normal rough and semifinitrturning 130 Extrasheavy-duty rough Cuming 1.60-3.00 Milling: Slab ming 110. End mailing tro, Light and medium face milling s0-1.25 Extrasheavyeduty face milling F306 Dailling: Normal ariling 130 Darling hard-to-machine materials and dling with a very, ‘ll drill 150. Broaching: Normal broaching 105-1110 Heavy-duty surface broaching Boot. TFor planing and shaping, use values given for taraing,MACHINING POWER ava ‘Table 28. Machine Tool Efficiency Factors, E 4 Taber E Type of Dive z Direct Belt Dive = Geared Head Dive | oge-oB Back Gear Dive os Girtiyarauie Deve | 0o-a90 C = feed factor for power constant (see Table 26) W = tool wear factor {Gee Table 27) E = machine tool efciency factor (see Table 28) xutting speed, rpm f= feed rate for turning; in/rev. or mm/rev feed rate for planing and shaping; in/stroke, or mm/stroke feed per tooth; in/tooth, or mm/tooth eed Fate; in/min. or mm/min maximum depth of cut per tooth: in., or mm depth of cut; in, or mm umber of teeth on milling cutter ine = number of teeth engaged in work ‘© = width of eut;in., or mam Example: A 180-200 Bhn AISI shaft is to be tuned on 2 geared head lathe using a cutting speed of 350 fpm (107 m/min), a feed rate of 0.016 in rev (0.40 mmvrev), and a ‘depth of cut of o.100 inch (2.54 mma). Estimate the power at the cutting tool and at the ‘motor, using both the inch and metric data. Inch units: Kp = 0.62 (from Table 23) C = 0.94 (from Table 26) 130. (from Table 27) EF = 080 (from Table 28) Q = 12 Vf = 12 x 350 X 0.016 X 0.100 (from Table 29) = 6:72 inS/min Pe = KpCOW = 062 X 0.94 X 6.72 X 130 = 5 hp Pe E080 ‘SI metric units: K, = 1.60 (from Table 23) C = 0.94. (from Table 26) W=130 (from Table 27) E = 0.80 (from Table 28) 6.25 bp O-Epa= 22x 040% 254 (from Table 29) = 181 m/s Pe fa Table 29. Formulas for Calculating the Metal Removal Rate, Q ‘Metal Removal Rate For Inch Units Only | For SI Mewie Units Only Operation Q = in min Qa en'ls Single-Point Tools rai yy (Cumming, Planing, and Shaping) vi eft Law Miling Srv = v, Surface Broaching 12Vimeds Pine nn1046 MACHINING POWER Whenever possible the maximum power available on a machine tool should be used when heavy cuts must be taken. The cutting conditions for utilizing the maxi- ‘mum power should be selected in the following order: 1. select the maximum depth of cut that can be used; 2. select the maximum feed rate that can be used; and, 3. estimate the cutting speed that will utilize the maximum power available on the machine. This order is based on obtaining the longest tool life ofthe cutting tool while at the same time obtaining as much production as possible from the machine. The life of a cutting tool is most affected by the cutting speed, then by the feed rate, and Yeast of all by the depth of cut. The maximum metal removal rate that given machine is capable of machining from a given material is used as the basis for estimating the cutting speed that will utilize all of the power available on the machine. Example: A .125 inch deep cut is to be taken on a 200-210 Bhn AISI 1050 stec! part using a 10 hp geared head lathe. The feed rate selected for this job is .or8 in /rev. Estimate the cutting speed that will utilize the maximum power available on the lathe. K,=.85 (From Table 23) 92 (From Table 26) W=1.30 (From Table 27) E=.80 (From Table 28) PE 10x80 Oe Fae =7.87 inJimin Qner___ 1.87 - W2fd 12x .018 x 125 Grn vie = 290 fpm Example: A 160-180 Bhn gray iron casting that is 6 inches wide is to have ¥ inch stock removed on a 10 hp milling machine, using an & inch diameter, 10 tooth, indexable insert cemented carbide face milling cutter. The feed rate selected for this cutter is .o12 inJtooth, and all of the stock (.125 in.) will be removed in one cut. Estimate the cutting speed that will utilize the maximum power available on the machine. K, = 52 (From Table 24) C = 1.00 (From Table 26) W = 1.20 (From Table 27) E = 80 (From Table 28) 10% 80___ 14.83 in.Ymin ( scon) "ax 100x120 _ 12.82, = fo = Set india (= fama) fost g 72 yo pm Guha’) fy 012 X10 DN _=x8x 14 nV Sar oe (=) #MACHINING POWER, 1047 ‘Table 30. Work Material Factor, Kg, for Drilling with a Sharp Drill ‘Work Material ‘Work Material Constast, Ke "AIST 117 (Resulfurized free machining mild steel) 12,000 ‘Steel, 200 Bhan 24,000 Steel, 300 Bha $31,000 Steel, 400 Bho 34,000 Cast loo, 150 Bh 14,000 ‘Most Alumioum Alloys 7,000 Most Magnesium Alloys: 4,000 ‘Most Brasses| 14,000 ‘Leaded Brass ‘Austenitic Stainless Stee! (Type 3:6) 24,000" for Torque Se.o00" for Thrust 18,0004 for Torque 29,000" for Thrust René 41 oR 49,000" min Hastelloy-C 30,000" for Torque $7,000" for Thrust * Values based upon a lnnited number of teste, 1 Willinerease with rapid wear ‘Estimating Drilling Thrust, Torque, and Power. — Although the lips of a drill cut metal and produce a chip in the same manner as the cutting edges of other metal cutting tools, the chisel edge removes the metal by means of a very complex combi ation of extrusion and cutting. For this reason a separate method must be used to Estimate the power required for drilling. Also, it is often desirable to know the mag- titude of the thrust and the torque required to drill a hole. The formulas and tabular data provided in this section are based on information supplied by the National Twist Drill Division of Regal-Beloit Corp. The values in Tables 30 through 33 are for sharp drills and the tool wear factors are given in Table 27. For most ordinary drilling operations 1,30 can be Used as the tool wear factor. When drilling most dificult-to- Muachine materials and when the drill is allowed to become very dull, 1.50 should be Used as the value of this factor. It is usually more convenient to measure the web thickness at the drill point than the length of the chisei edge; for this reason, the approximate wid ratio corresponding to each cld ratio for a correctly ground drill is provided in Table 33. For most standard twist drils the e/d ratio is -18, unless the Bail has been ground short or the web has been thinned. The c/d ratio of split point drills is .03. The formulas given below can be used for spade drills, as well as for Titanium Alloy TH6A 4 40Re cert anil Separate formulas are required for use with customary inch units and for SI metric unis. For inch units only: T= 2K iF FrBW+KPIW @) M= KiFuAW @ P.= MNI63.025 ® For SI metric units only: T= 0.05 Kak pF BW + 0.007 KyJW Gy M Affui 0.000025 KifiFuAW o P. = MNI9350 ®1048 ‘MACHINING POWER ‘Use with either inch or metric units: Pe Py ate = o Where: P, = Power at the cutter; hp, or kW ywer at the motor; hp, or kW ‘4M = Torque; in. Ib, or Nm T= Thrust; Ib, or N Kg= Work material factor (See Table 30) y= Feed factor (See Table 31) Fr = Thrust factor for drill diameter (See Table 32) Fyc= Torque factor for drill diameter (See Table 32) hisel edge factor for torque (See Table'33) B= Chisel edge factor for thrust (See Table 33) J'= Chisel edge factor for thrust (See Table 33) W= Tool wear factor (See Table 27) N= Spindle speed; rpm E= Machine tool efficiency factor (See Table 28) D= Drill diameter; in., or mm - c= Chisel edge length; in., or mm (See Table 33) w = Web thickness at drill point; in., or mm (See Table 33) Example: A standard % inch drill is to drill steel parts having a hardness of 200 Bhn on a drilling machine having an efficiency of .80. The spindle speed to be used is 350 rpm and the feed rate will be .008 in /rev. Calculate the thrust, torque, and power Tequired to drill these holes: Ky = 24,000 (From Table 30) (From Table 31) (From Table 32) (From Table 32) (From Table 33) (From Table 33) (From Table 33) W=130 (From Table 27) T= 2K EP BW+ KW = 2X 24,000 X .021 X 899 X 1.355 X 1.30 + 24,000 X 875? X .030%1.30 = 2313 1b M~ Kg EwAW Speen 1.085 x 1.30= 559 in. Ib iS = 559% 350 ceases a aad 63,025 "E080 ‘Twist drills are generally the most highly stressed of all metal cutting tools. They must not only resist the cutting forces on the lips, but also the drill torque resulting from these forces and the very large thrust force required to push the drill through the hole. Therefore, in many instances when drilling smaller ees the twist drill ct the 1 bp. 9 bpMACHINING POWER 1049 Table 31. Feed Factors, F,, for Drilling Tach Uae Steere Was Fed, Fee Fed, Feed, wer | om ll inter | x |lmmnv | x | eee | -eoos [oor ff or | oxo ff oor | 00s) oso | as wor | coe ff ois | ar ff ces | ce |] o3s | Se so | ‘oor |] lors | cas |} oes | oor ff ceo | te om | io |] oe | ‘xe | co | iy fl os | te seq | corr |] coro | oe ff ovo | lige |] ose | Se cos. | ory ff or | oy ff om | ces f] oe ere woe | cot |] os | Se fl oe | ae | 3 78 vor | om |] coo | co ff cs | au | o% 294 wot | lor [ss | oss] ose | Soe fl om | 38 soo | ley cee | coe |] oss | Se || oe | 28 wo | os | ‘cso | ‘on |] cas | Sse |] ss | ee Table $2, Drill Diameter Factors: F, for Thrust; Fy for Torque Inch Units ‘SI Metric Units _] Brit Dall Dail Drill bin... F | Fy foam! Fry foam! Fy | re fbotm.| x | zy “26s | a0 +6 | 245 | 235]| 2200] ana6 | seme cong | ase nao | 202 | 484 s4c0| az | soe ong | 18 ate | rsa} das |f isso | asa | soe 336 | “a8 tao | 509 | sass sh00 ure cae | ey tae | Sst | seas || Sess nse 219 | “297 $60] 37 [azaa] 5200 Sine ise S40 | ca: |3ssef Ss fou RY 720] 8s |e] 3800 e186 a3 hoo | S26 [4s || eco e53 a #40 | 5.96 | 503] 45.00 a8 ns aso | G06 |Sr2s|| atco| 203 [roe “a8 | sr xiao | 63 [7430 seco] 228 frses seo | ‘$74 1250 | 754 [9426] soo] 2575 [ease es | oe tase | S49 | 3 |] seo | 2088 (srt ‘es | ‘ser 5:9 | 147-|] 70.00] 29.05 {2005 os | a sar | 128] 76.00| se9e [seco rse | “354 15.00 | 10.54 | 300.3 || go.00| 3633 |s205 as | 20.00 | 1038 | 19:7 [ooo | 35. [sot Table39. Chisel Edge Factors for Torque and Thrust Torque | Tarox | Throat Tague | Tht | Ths ag |APpi™ | Factor | Factor | Factor |{ ce [Armee | Foriae | First | hes = A z J A B J ais | 000 | xaco | oor Jf ae | ass | res | va] a0 sass | tog | te | os [ae | os [oases | ame | 2 oe | vos | race | foe Ws | are [ies | cee | ee cats | xo | ras | core |] Se | Se | sass | eles | ooo sno | rey | rar | ou fas | 300 | tars | gos | se sao_| roto | ssro_f oa Uf ae | 50 | rss | cece | too For drils of standard design, use cid = 28. For split point drills, use cid = os: ld = Length of Chisel Edge + Drill Diameter. ‘eld = Web Thickness at Drill Point + Dri Diameter,