5cuttingconditions 170204214737

BACHELOR OF ENGINEERING
MANUFACTURING TECHNOLOGIES
CUTTING CONDITIONS
CUTTING
CONDITIONS
Feed rate
Spindle Speed
Radial cutting depth
Axial cutting depth

by Endika Gandarias
Dr. ENDIKA GANDARIAS MINTEGI
Mechanical and Manufacturing department
Mondragon Unibertsitatea - www.mondragon.edu

(Basque Country)
www.linkedin.com/in/endika-gandarias-mintegi-91174653
by Endika Gandarias 2
CONTENTS
BIBLIOGRAPHY
CUTTING TOOLS
CUTTING PARAMETERS
CUTTING FLUIDS
SELECTION OF CUTTING CONDITIONS
GLOSSARY
BIBLIOGRAPHY
BIBLIOGRAPHY
BIBLIOGRAPHY
The author would like to thank all the bibliographic references and videos that
have contributed to the elaboration of these presentations.
For bibliographic references, please refer to:
http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)
http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)
For videos, please refer to:
www.symbaloo.com/mix/manufacturingtechnology
CUTTING TOOLS
CUTTING TOOLS
CUTTING TOOLS
(HSS)
VIDEO VIDEO
CUTTING TOOLS
CUTTING TOOLS
Temperature [C]
C
1550 Ceramic
1400 CBN
1300 Carbide
(Hard metal)
Hardness [HRC]
900 Diamond
800 HSS
CUTTING TOOLS
Feed [mm/rev]
Cutting speed [m/min]

50
CUTTING TOOLS
TOOL GEOMETRY
Turning
Solid tool Brazed insert Mechanically clamped insert
VIDEO
CUTTING TOOLS
TOOL GEOMETRY
Turning RAKE FACE

Side rake angle
Major (or side) cutting edge
Minor (or end) Front or back rake angle
cutting edge angle Nose (or corner) radius
MAJOR CLEARANCE (FLANK

Minor (or end) cutting OR RELIEF) FACE
edge Side clearance (or relief) angle
Major (or side or lead) cutting edge angle

MINOR CLEARANCE
(OR FLANK) FACE Front Clearance (or end-relief) angle
Rake angle
Side rake angle Minor cutting
edge angle
RAKE FACE
Major cutting
CLEARANCEF edge angle
Side clearance Clearance angle ACE
angle
VIDEO
CUTTING TOOLS
TOOL GEOMETRY
Milling
END MILLING CUTTERS PERIPHERAL AND FACE MILLING CUTTERS
Flat Ball nose Corner radius Shell Side and Face Single and double
End Mill End Mill End Mill End Mill cutter angle cutter
CUTTING TOOLS
TOOL GEOMETRY
Drilling
Main cutting
Chisel edge edge
Point angle
Minor cutting Web
Major thickness
edge
flank face
Drill diameter
Helix
Major
angle
cutting edge
Major
Margin flank face
Rake face Rake face
High Speed Steel (HSS) Solid carbide drill
Point angle Point angle

118 140
VIDEO
CUTTING TOOLS
TOOL INSERT
Insert design
Cheap-breaker
macrogeometry
Cutting edge
reinforcement of 0,25 mm
Rake angle 20
Cheap-breaker
macrogeometry Main facet 5
Geometry for small

cutting depths (ap)
Main cutting edge

design
Tip cutting edge design
VIDEO
CUTTING TOOLS
TOOL INSERT
Insert material types
ools
de t
c arbi
ools ted
i de t Coa
rb
ate d ca
No n- c o
cs
e ram i
C
et
Cerm
iam ond
de) ine d
Nitri ys t a ll
ron yc r
c Bo Pol
( C ubi
CB N
CUTTING TOOLS
TOOL INSERT
Rake angle Clearance angle
POSITIVE NEGATIVE
Increased tool insert resistance.
Clearance angle always > 0.
Lower cutting forces. Higher cutting forces.
Longer chip length. Shorter chip length.
Clearance angle > 0. Clearance angle = 0.
Used for internal machining. Double side inserts.
VIDEO
CUTTING TOOLS
TOOL INSERT
Side Rake angle Lead angle / Entering angle
Entering angle
Lead angle
Same advantage discussed for
rake angle, applies to side rake
angle.
When rake angle is positive so is
side rake angle, and vice versa.
CUTTING TOOLS
TOOL INSERT
Nose radius and Nose angle Chipbreaker
Groove type Obstruction type
Each insert has an

appliation area.
Nose radius Nose angle
CUTTING TOOLS
TOOL INSERT
Insert grade
VIDEO VIDEO VIDEO
VIDEO
CUTTING TOOLS
TOOL INSERT
Insert fabrication Powder fabrication VIDEO

Raw material Crushed
Tantalum
Niobium
Titanium
Tungsten
Cobalt carbide
Spray drying
Carbide powder
Ready to be pressed
CUTTING TOOLS
TOOL INSERT
Insert fabrication Pressing

Upper and lower
die
Pressing force
20 - 50 t
Die and
center pin
CUTTING TOOLS
TOOL INSERT
Insert fabrication Sintering
Sintering duration: 8 hours

Inserts trays Temperature between 1200 - 2200 C
Insert contraction
(18% in all directions,
50% in volume)
CUTTING TOOLS
TOOL INSERT
Insert fabrication Insert grinding
Higer and lower face Free profiling Profiling
Beveling, negative facet Peripheral
Faceta
neg.
Bisel
CUTTING TOOLS
TOOL INSERT
Insert fabrication Insert grinding
ER Treatment W/H proportion depends on

(Edge Roundness) the application
CUTTING TOOLS
TOOL INSERT
Insert fabrication Chemical Vapor Deposition (CVD) coating
CVD oven
- Large coating thickness. Inserts trays
- Mechanical wear resistance (TiCN).
- Thermal & chemical resistance (Al 2O3).
Al2O3
TiCN
Substrate
CUTTING TOOLS
TOOL INSERT
Insert fabrication Physical vapor deposition (PVD) coating

PVD oven
- Thin coating thickness.

- Sharp cutting edge.
- Good edge toughness.
- Used in all monoblock rotating tools.
- Can be used with soldered tips.
TiN
Substrate
CUTTING TOOLS
TOOL INSERT
Insert fabrication Visual inspection, marking, packaging
Marking
Visual inspection
Packaging
Labelling
Distribution
CUTTING PARAMETERS
CUTTING PARAMETERS
CUTTING PARAMETERS
SELECTION CRITERIA:
Make the highest profit considering the technical requirements.
OPERATIONS:
ROUGHING: It aims to remove as much as possible material from the workpiece for as
short as possible machining time. Quality of machining is of a minor concern.
FINISHING: The purpose is to achieve the technical requirements (i.e., dimensional,
surface and geometric tolerances). Quality is of major importance.
In order to make most profit the most relevant variables are: ROUGHING FINISHING
Cutting time.
Cutting tool expenditure. Vc

Machining parameters that most affect the above variables are: fz
Cutting speed (Vc)
Feed (fz, fn, F)
fn
F
Radial and axial depth of cuts (ap, ae)
CUTTING PARAMETERS: TURNING
1. Cutting Speed (Vc)
DEFINITION: Relative linear speed at the contact point between tool and the workpiece.
Vc: Cutting speed (m/min)

Vc 1000 N=
Dm N: Spindle speed (rpm)
Dm: machined diameter (mm)
VIDEO
VIDEO
VIDEO
VIDEO
Given the following parameters calculate

the spindle speed for each diameter:
Cutting speed Vc = 120 m/min

Diameter D1 = 50 mm
Diameter D2 = 80 mm
VC x 1000
N=
xd
N1
N2
2. Feed
DEFINITION: Relative movement between the workpiece and the tool.

F
FEED PER
IN REVOLUTION
TURNING (fn)
FEED RATE
FEED PER REVOLUTION or
FEED PER MINUTE
fn [mm/rev] F = fnN F [mm/min]
3. Cutting depth (ap)

ap
ap
ap
WORKPIECE Vc fn Ap
MACHINE TOOL MATERIAL OPERATION
MATERIAL (m/min) (mm/rev) (mm)
D 30 40 D 0.1 0.25 D 0.75-2
Turning and facing
A 40 - 50 A 0.02/ 0.1 A 0.2-0.8
Parting and grooving 10 15 0.02 0.1
HIGH SPEED STEEL Threading 10 Thread pitch According to formula

(HSS) Drilling 18 Manual
ORIENTATIVE CUTTING TABLE FOR EXERCISES
Knurling 10
D 20 30 D 0.1 0.25 D 0.75-2
STEEL Boring
A 30 - 40 A 0.02/ 0.1 A 0.2-0.8
D 80 100 D 0.1 0.25 D 0.75-2
Turning and facing
A 100 - 120 A 0.02/ 0.1 A 0.2-0.8
HARD METAL Threading 40 - 50 Thread pitch According to formula
Drilling 30 40 Manual
Boring
D 70 90 D 0.1 0.25 D 0.75-2 D: Roughing operation
TURNING A 90 - 110 A 0.02/ 0.1 A 0.2-0.8 A: Finishing operation
MACHINE D 40 60 D 0.1 0.25 D 0.75-2
Turning and facing
A 60 - 80 A 0.02/ 0.1 A 0.2-0.8
HIGH SPEED STEEL Threading 15 Thread pitch According to formula

(HSS) Drilling 30 Manual
Knurling 20
D 30 50 D 0.1 0.25 D 0.75-2
ALUMINIUM Boring
A 50 - 70 A 0.02/ 0.1 A 0.2-0.8
D 150 180 D 0.1 0.25 D 0.75-2
Turning and facing
A 180 200 A 0.02/ 0.1 A 0.2-0.8
HARD METAL Threading 50 60 Thread pitch According to formula
Drilling 60 80 Manual
D 140 170 D 0.1 0.25 D 0.75-2
Boring
A 170 - 190 A 0.02/ 0.1 A 0.2-0.8
SURFACE ROUGHNESS:
Surface finish depends on:

Tool nose radius
Feed per revolution (fn)
WIPER INSERTS: Advantages:
Productivity VIDEO
TOOL CENTRE HEIGHT
VIBRATION
_ Vibration
+
+ + Round
R
90
S
80
C
Vibration
Strength
80
W
60
T
55
D
ER: Edge Rounding
_
GC: Ground coated inserts
35
VB: Flank wear
_ V
VIBRATION
Dampened tools
They can reduce machining vibration in turning, milling or
drilling. Dampened tool
Undampened tool
Diameters starting from > 10mm.

Maximum overhang value 14 .
VIDEO VIDEO
Spindle Speed Variation (SSV)
SSV technique may reduce or eliminate chatter.

VIDEO
CUTTING PARAMETERS: MILLING
Vc 1000 Vc: Cutting speed (m/min)

N= N: Spindle speed (rpm)
Dc Dc: Tool diameter (mm)
VIDEO
2. Feed

FEED PER
IN TOOTH
MILLING (fz)
Feed per tooth (fz): It defines the chip thickness, and so, the load that
the tool is subjected to.
VIDEO fn
Feed per revolution (fn): It defines the tool displacement per tool
revolution.
fn = fzz z tooth number (flute number)
Feed rate or Feed per minute (F): It defines the tool movement speed.
F = fnN = fzzN N spindle speed
3. Cutting depth
As there are greater tooth breakage chances
during tooth entry and exit, in facing operations
the following tool size and positioning are
recommended.
ap: axial depth of cut
Better size
ae : radial depth of cut
Better positioning
VIDEO
WORKPIECE Vc fz Ap Ae
MATERIAL (m/min) (mm/tooth*rev) (mm) (mm)
D 20 - 25 0.05 0.1 D 1-2 D (~2/3)
Face milling A (~2/3)
A 25 - 30 0.01 0.05 A 0.2-0.5
HIGH SPEED D (10%-25%)
D 20 - 25 0.05 0.1 D (50%-80%)
STEEL
ORIENTATIVE CUTTING TABLE FOR EXERCISES
Side milling A (5%-10%)

A 25 - 30 0.01 0.05 A (50%-80%)
(HSS)
D 15 - 20 0.05 0.1
Other milling
A 20 - 25 0.01 0.05
STEEL D (~2/3)
D 80 - 100 0.05 0.1 D 1-2
A 100 120 0.01 0.05 A 0.2-0.5
D 80 - 100 0.05 0.1 D (50%-80%) D (10%-25%)
HARD METAL A 100 120 0.01 0.05 A (50%-80%)
D 70 - 90 0.05 0.1
Other milling
MILLING A 90 100 0.01 0.05
MACHINE D 50 - 70 0.05 0.1 D 1-2 D (~2/3)
A 70 - 90 0.01 0.05 A 0.2-0.5
HIGH SPEED D (10%-25%)
D 50 - 70 0.05 0.1 D (50%-80%)
STEEL Side milling A (5%-10%)
A 70 - 90 0.01 0.05 A (50%-80%)
(HSS)
D 40 - 60 0.05 0.1
Other milling
A 60 - 70 0.01 0.05
ALUMINIUM
D120 - 150 0.05 0.1 D 1-2 D (~2/3)
A 150 180 0.01 0.05 A 0.2-0.5
D120 - 150 0.05 0.1 D (50%-80%) D (10%-25%)
HARD METAL A 150 180 0.01 0.05 A (50%-80%)
D100 - 130 0.05 0.1
Other milling
A 130 150 0.01 0.05
Other milling: slot milling, t-shape milling, dovetail milling, form milling.
D: Roughing operation
A: Finishing operation
MILLING DIRECTION MILLING: Discontinuous cutting process
DOWN MILLING or CLIMB CUTTING UP MILLING or CONVENTIONAL MILLING

Same cutter rotation and feed Opposite cutter rotation and feed
Mc Mc
Ma
Ma
The insert starts cutting with a large chip thickness: The insert starts cutting at zero chip thickness:
It is more suitable. Rubbing Friction , Fc , Machine power
Backlash elimination is necessary. Vibration tendency . Temperature , work-hardened surface, Ra
Fc tend to pull the workpiece into the cutter. Fc tend to: lift the workpiece from the table, push the
cutter and workpiece away from each other.
Not recommended when using ceramic inserts (fragile).
Tensile stresses when teeth exit, tool life
VIDEO VIDEO VIDEO
HIGH SPEED MACHINING (HSM)
In comparison with traditional milling:

Spindle speed (N) , feed rate (F) and axial cutting depth (ap) .
Radial cutting depth (ae) and feed per tooth (fz) .
F F
HSM: Feed faster Traditional milling: time for

than heat heat propagation.
propagation.
VIDEO
Trochoidal milling Progressive cutting Constant peripheral

(typical HSM technique) (constant stock) cutting speed (Vc)
CHARACTERISTICS:
More productive cutting process in small sized components.
Possible to be used with high-alloy tool steels up to 60-63 HRc (EDM process can be avoided).
Excellent surface roughness can be achieved (Ra ~ 0.2 m).
Machining of very thin walls is also possible.
Typical applications: dies and moulds, difficult to machine materials,
DISADVANTAGES:
Higher maintenance costs: Faster wear of guide ways, ball screws and spindle bearings.
Specific process knowledge, programming equipment and interface for fast data transfer is needed.
It can be difficult to find and recruit advanced staff.
Human mistakes, hardware or software errors give big consequences. Emergency stop is practically
unnecessary.
Good work and process planning necessary.
Safety precautions are necessary:
Machines with safety enclosing (bullet proof covers).
Avoid long overhangs on tools.
Do not use heavy tools and adapters.
Check tools, adapters and screws regularly for fatigue cracks.
Use only tools with posted maximum spindle speed.
Do not use solid tools of HSS.
MILLING STRATEGY
When using a ball nose end mill, tilting the cutter

10 to 15 degrees can improve tool life and chip
formation and provide a better surface finish.
ROLL-IN TECHNIQUE
VIDEO
MILLING STRATEGY
MILLING STRATEGY
WEAK FIXTURE
THIN WALLS
ae sould be minimized (20% Dc).
ap should not exceed 100% Dc
Big entry-exit radii should be programmed.
Sharp and positive cutting edges should be used.
MILLING STRATEGY
CENTER-LINE OF THE CUTTER CENTER-LINE OF THE CUTTER CENTER-LINE OF THE CUTTER

INSIDE THE WORKPIECE IN LINE WITH THE WORKPIECE OUTSIDE THE WORKPIECE
ae > 70% x Dc ae < 25% x Dc

hex < fz high productivity hex = fz cutter hits, no shearing hex < fz F to mantain productivity
CVD coating inserts recommended PVD coating inserts recommended

(better thermal protection) (sharper cutting edge)
Carbide handles the compressive stresses at the impact of entering well.
VIDEO VIDEO VIDEO

MILLING STRATEGY
CENTER-LINE OF THE CUTTER CENTER-LINE OF THE CUTTER CENTER-LINE OF THE CUTTER

INSIDE THE WORKPIECE IN LINE WITH THE WORKPIECE OUTSIDE THE WORKPIECE
Chip thickness is at its maximum
At exit, chip bends and generates tensile forces on the carbide increasing fracture possibilities.
VIDEO
ENTERING ANGLE (Kr) : Cutting edge angle affects the cutting force direction and the chip thickness.
90 45 10 VIDEO
+
Chip thickness _
_ Length of contact
+ Best for face milling & profiling operations.
Excellent ramping capabilities.
Best for shoulder face milling Best for face milling & plunge milling. Strongest cutting edge with multiple
& where 90 form is required. Excellent for ramping operations. indexes.
Low axial forces Thin walls, Lower radial forces Lower vibration. The chip load and entering angle
weak fixtured components, Chip thickness feed to keep productivity. vary with the depth of cut.
VIDEO VIDEO VIDEO VIDEO

PITCH (u)
The pitch is the distance between the effective cutting edges.
Different pitches:
Productivity
_
Machine power consumption
+
Vibration
Differential pitch: A very effective way to minimize vibration tendencies.
VIDEO
TOOL HOLDER ALIGNMENT RECOMMENDATIONS:
Roughing Finishing
< 0.006 mm
Attention to the max. allowable torque.

It depends on the tool holder type and tool diameter.
Tool overhang (A) and total length

(B) should be minimized.
SURFACE ROUGHNESS:
Surface finish, i.e. Surface Roughness, is mainly determined by the distance between the
contiguous toolpaths, tool radius and surface slope.
How to calculate the axial (ap) and radial (ae) cutting depths to
achieve a certain theoretical roughness?
ae = Radial depth of cut
ap = Axial depth of cut
Rmax = Rz = Max. roughness
Rhta = Tool radius
= Surface slope
In this type of milling; Ra Rmax/4
ae
Rmax ap
Rhta
EFFECTIVE TOOL RADIUS
In ball end mills, cutting happens at points with different diameters. Thus, as the whole tool rotates at
the same spindle speed, the cutting speed varies along the ball end.
Effective radius in ascending toolpaths Effective radius in descending toolpaths
CUTTING PARAMETERS: DRILLING
N Vc 1000 Vc: Cutting speed (m/min)

N
N= N: Spindle speed (rpm)
Dc Dc: Tool diameter (mm)
vc
VIDEO VIDEO
2. Feed
FEED PER
IN REVOLUTION
DRILLING
(fn)
FEED RATE
or
FEED PER MINUTE F = fnN
F [mm/min]
3. Cutting depth (ap)

VIDEO
ap
DRILL ALIGNMENT RECOMMENDATIONS:
Rotary drill Stationary drill

VIDEO VIDEO
0.02 mm 0.02 mm
Tool alignment method.
B
A
Feed force
Better B than A tool position

(lower torque).
ENTRY AT NON-PLANAR SURFACES:
A B C D
fn fn fn fn
ORIENTATIVE CUTTING TABLE
WORKPIECE Vc fn
MATERIAL (m/min) (mm/rev)
Spot drilling 18 0.04 0.1
FOR EXERCISES
HIGH SPEED STEEL Drilling 18 0.04 0.1

STEEL
(HSS) Counterboring 9
DRILLING Countersinking 9
MACHINE Spot drilling 30 40 0.04 0.1
HIGH SPEED STEEL Drilling 30 40 0.04 0.1
ALUMINIUM
(HSS) Counterboring 15 20
Countersinking 15 20
CHIP CONTROL
Excellent Acceptable
The chip formation is acceptable when chips can be
evacuated from the drill without disturbance.
The best way to identify this is to listen during drilling:

A consistent sound = chip evacuation is good.
An interrupted sound indicates chip jamming.
Chip jamming can cause radial movement of the drill Chip jamming
and affect hole quality, drill life and reliability, or
drill/insert breakages.
A hole with good chip evacuation. A hole affected by chip jamming.

Start chip
The start chip from entry into the workpiece is always
long and does not create any problems.
VIDEO
PECK DRILLING
Peck drilling may be necessary if chip evacuation is difficult due to a deep hole or the
use of external lubricant.
VIDEO
CUTTING PARAMETERS
SUMMARY TABLE
HOW TO
VARIABLE UNIT DESCRIPTION TURNING MILLING DRILLING
CALCULATE?
Vc m/min Cutting speed TABLES
N rpm or rev/min Spindle speed N=(Vc*1000)/(*)
fz mm/tooth*rev Feed per tooth TABLES
TABLES
fn Feed per
mm/rev
revolution
fn = fz * z
Feed rate or F = fn * N
F mm/min
feed per minute
TABLES
Ap Axial cutting
mm
depth
Tool radius
Ae Radial cutting
mm TABLES
depth
Parameter introduced into the machine.
Parameter NOT introduced into the machine.
CUTTING FLUIDS
CUTTING FLUIDS
CUTTING FLUIDS
Cutting fluid is any liquid or gas that is applied to the chip or cutting tool to improve cutting performance.
Cutting fluids serve 4 principle functions:
1. To remove heat in cutting (=COOLING): The energy used in the cutting process is almost
exclusively transformed into heat that goes to the workpiece, tool and chip. The effective cooling
action depends on the method of application, type of fluid, fluid flow rate and pressure.
2. To lubricate the chip-tool interface (=LUBRICATION): It reduces friction forces and

temperatures.
3. To wash away chips (=CHIP REMOVAL): This is only applicable to small and discontinuous
chips.
4. To avoid part oxidation (=ANTI-CORROSION): The environment humidity in combination with

the high temperatures (500-900C) obtained during machining may cause part oxidation. Thus,
the cutting fluid must contain anti-corrosion additives.
Use of cutting fluids contributes to:

Diminish tool wear (longer tool life).
Produce workpieces of accurate sizes (reduce thermal expansion).
Achieve proper surface quality of the workpiece.
Support chip removal.
Reduce thermal stress on machine tool.
CUTTING FLUIDS
- METHODS OF APPLICATION
LUBRICATIO USED
CONTENT CHARACTERISTICS
N TYPE VOLUME
Used for manual tapping. Cutting fluids are used as

Manual application
lubricants.
Lubricating system of machine tools need to be cleaned

Flooding supply
from time to time to eliminate microorganisms.
Wet machining 10 to 100
(using coolant) l/min Some tools (typically drills) are provided with axial holes
Coolant-fed tooling
so that cutting fluid can be pumped directly to the
or internal cooling
cutting edge. Coolant pressures up to 80 bars.
VIDEO
Coolant-fed tool Special tool holders required for milling, turning or
holders drilling operations. Coolant pressures up to 30 bars.
Cutting fluid is deposited as drops or air-oil mix. Valid

Reduced Minimum quantity 50 ml/h up
for not very demanding machining operations.
lubrication llubrication (MQL) to 1-2 l/h
It can be external or internal. VIDEO
Without It shows economic and environmental benefits. Under
Dry machining without
lubrication research.
Novel cooling methods are under research: high pressure cooling (> 70bar), criogenic cooling (N2, CO2),...
CUTTING FLUIDS
Manual application Flooding supply Coolant-fed tooling Coolant-fed tool holder
+
+
Titanium alloys
lty
lty
Nickel Broaching
cu
cu
Stainless steel Shaping
ffi
ffi
Hard steel ( 0.4 to 0.7 % C ) Gear machining
di
di
Copper Drilling
ng
g
Cast-iron Reaming
in
ni
Steel (More carbon more difficult) Sawing
in
hi
ch
Aluminum Milling
c
Ma
Ma
Brass Turning
Bronze
Zinc alloy
-
-
CUTTING FLUIDS
- TYPES OF CUTTING FLUID
Cutting oils are based on mineral or fatty oil mixtures. Commonly used for heavy cutting operations.
Soluble oils is the most common (95% of the time), cheap and effective form of cutting fluid. Oil droplets
suspended in water in a typical ratio water to oil 30:1. Emulsifying agents are also added to promote stability
of emulsion, as well as anticorrosive additives.
Chemical fluids (synthetic) consists of chemical diluted in water. They may have harmful effects to the skin.
Low speed applications

Cutting oils (broaching, threading,)
Soluble oils
Chemical fluids High friction
Water
Lubrication
Maximum lubrication
Dry machining
High speed applications
(turning, milling,)

Low friction

Maximum refrigeration
Refrigeration
SELECTION OF
CUTTING CONDITIONS
Productivity is a combination of factors that really make a difference, such as:
Increased cutting conditions = more parts per hour

Predictable tool life = machining security
Fewer tool changes = less down time
Fewer rejects = higher quality more valuable end product
Product availability = less inventory
Technical training of employees = better understanding and less scrap
Important to identify the most relevant factors that influence the FINAL COST:
3%
17%
27%
31%
22%
Important to identify the most relevant factors that influence MACHINE-TOOL UTILIZATION TIME:
Machining efficiency suggests that good quality parts are produced at reasonable cost and at high
production rate.
Most relevant cutting parameters that affect machining costs and productivity are:
1. Depth of cut
2. Feed
3. Cutting speed
1. Depth of Cut (ap, ae)

It is predetermined by workpiece geometry and final part shape.
In Roughing operations As large as possible (max. 6-10 mm).

It depends on machine tool, cutting tool strength and other factors.
In Finishing operations A single pass to achieve the final dimensions.
Roughing passes in a turning operation Finishing pass in a turning operation
2. Feed (F, fn, fz)
In Roughing operations As large as possible (max. 0,5mm/rev).

It depends on cutting forces and setup rigidity.
In Finishing operations Small to ensure good surface finish (~ 0,05-0,15 mm/rev).

Cutting at high cutting speed involves...
Reduction of tool life Increase of production costs

as more cutting tools are needed.
Increase of productivity less time consumption.
Hence, optimal cutting speed range has to be calculated for:
Cutting speed for minimum cost per unit (V min).

Cutting speed for maximum production rate (V max).
Parts per hour

Cost per part
Production cost
Tooling cost
Fixed costs
Machinery costs
Economic High efficiency Vc for Cutting speed Vc

Vc range max. productivity
- HOW TO CALCULATE THOSE VALUES?
Several limitations need to be considered:
1. MACHINE
2. TOOL
3. GEOMETRY
4. MATERIAL
1. MACHINE: The machinery usually exists in the workshop, and it may be a limiting factor.
Anyway, either an existing or a new machine is used, attention should be paid to
the following machine features:
General characteristics: number of axes, machine configuration type, general

dimensions and weight,
Axes: traversing range, power, accuracy, max. workpiece weight, max.
acceleration and feed.
Workholder system: Forces, vibrations,
Spindle head: power, speed range, run-out, stiffness, clamping system,
automation possibilities, internal cooling.
Toolholder system: Run-out, torque,
Tool changer: chip to chip time, max. number of tools, tool length and diameter,
Cooling unit system: internal or external, MQL, HPC
CNC controller: capabilities

2. TOOL: Tool wear will occur.

There are five main wear mechanisms which dominate in metal cutting:
1. Abrasion.
2. Diffusion.
3. Oxidation (corrosion).
4. Fatigue (thermal).
5. Adhesion.
These wear mechanisms combine to attack the

cutting edge in various ways depending upon
the tool material, cutting geometry, workpiece
material and cutting data.
Flank wear is the most common type of wear

(abrasion) and the preferred wear type, as it
offers predictable and stable tool life.
VIDEO
2. TOOL
Load type Symbol Wear description Cause
Mechanical efforts on the

Mechanic cutting edge create tool
failures.
Temperature variations
Thermal create cracks in the
cutting edge.
Chemical reaction
between tool carbides
Chemical and the machining part
create wear.
SiC inclusions of Fe
Abrasive foundry materials may
create cutting edge wear.
FA
In the case of pasty
Adhesive materials, layers / new
edges are formed.
FA = Filo de
aportacin
TOOL WEAR TYPES
Inappropriate cutting conditions 1. Flank wear

2. Crater wear
Inappropriate tool features 3. Plastic deformation
Material properties 4. Notch wear
5. Thermal cracks
Too low or high cutting 6. Mechanical fatigue cracks
temperature 7. Chipping on edge
8. Tool breakage
9. Built-up edge (BUE)
VIDEO
Vc : Cutting speed [m/min]

fn : Feed per revolution [mm/rev]
ap : Cutting depth [mm]
T : Tool life [min]
a, b, n, C: Constants
VIDEO
INSERT GRADE
Workpiece
material hardness
R: Roughing
M: Medium machining Tool Vc
material ap
F: Finishing
fn
WORKPIECE MATERIAL
INSERT GRADES
Select geometry and grade

depending on the type of the
workpiece material and type of
application.
CUTTING DATA ON DISPENSERS TURNING INSERTS
When increasing the cutting speed (vc), feed rate (fn) should be
decreased and vice versa.
Cutting speed and feed data compensation for turning
GLOSSARY
GLOSSARY
GLOSSARY
ENGLISH SPANISH BASQUE

Alignment Alineacin Alineazio
Alloy Aleacin Aleazio
Aluminium casting Fundicin de aluminio Aluminio burdinurtua
Axial cutting depth Profundidad de pasada axial Sakontze sakonera
Backlash Desajuste Desdoitze
Ball nose end mill Fresa de punta esfrica / punta de bola Boladun fresa
Bend Doblar Tolestu
Beveling Biselado Alakaketa
Brass Latn Letoia
Brazed Soldado Soldatua
Breakdown Averiar Matxuratu
Broaching Brochado Brotxaketa
Bronze Bronce Brontzea
Built-up edge Filo de aportacin Aportazio ertza
Carbide Metal duro Metal gogorra
Carbon steel Acero al carbono Karbono altzairua
Cast-iron Fundicin Burdinurtu
CBN (Cubic Boron Nitride) Nitruro de Boro Cbico Boro nitruro kubikoa
Cheap breaker Rompevirutas Txirbil hauslea
Chip Viruta Txirbil
Chip Viruta Txirbil
Chipping Astillado Zati
Chisel edge Filo central Erdiko sorbatz
Clamp Abrazar Lotu
Clearance face Cara de incidencia Eraso aurpegia
Climb cutting Concordancia Konkordantzia
Coarse Basto Baldar
Coat Recubrimiento Estaldura
GLOSSARY

Contiguous Contiguo Alboko
Conventional milling Contraposicin Kontrajartze
Coolant Lubricante Lubrifikatzaile
Corner radius end mill Fresa trica Fresa torikoa
Crush Machacar Birrindu
Cutting edge Arista de corte Ebaketa ertz / Sorbatz
Cutting speed Velocidad de corte Ebaketa abiadura
Cutting tool Herramienta de corte Ebaketa erraminta
Dampened tool Herramienta antivibratoria Bibrazioen aurkako erraminta
Die Molde Molde
Diminish Disminuir Gutxitu
Dispenser Dispensador Kaxa
Dovetail Cola de milano Mirubuztan
Down milling Concordancia Konkordantzia
Drilling Taladrado Zulaketa
Drop Gota Tanta
Edge rounding Redondeo de arista Ertz biribiltze
EDM Electroerosin Elektro-higadura
Enclosing Cerramiento Itxitura
End mill Fresa plana Fresa laua
Engagement Empae Lausotua
Fatty Graso Oliotsu
Feed per revolution Avance por vuelta Aitzinamendua birako
Feed per tooth Avance por diente Aitzinamendua hortzeko
Feed rate Avance por minuto Aitzinamendua minutuko
Finish Acabado Akabera
Flank Flanco / Lateral Albo
Flooding Inundacin Gainezkatze
GLOSSARY

Friction Friccin Marruskadura
Gauge Calibrar Kalibratu
Gear Engrane Engranai
Grinding Rectificado Artezketa
Hard metal Metal duro Metal gogorra
Hardening Endurecimiento Gogortze
Hardness Dureza Gogortasuna
Harmful Daino Kaltegarri
Heat Calor Bero
Height Altura Altuera
High Speed Machining Mecanizado a alta velocidad Abiadura azkarreko mekanizazioa
High Speed Steel (HSS) Acero rpido Altzairu lasterra
Hit Golpear Kolpe
Insert Plaquita intercambiable Plakatxo trukagarria
Jamming Atasco Trabatze
Labelling Etiquetado Etiketa jarri
Load Carga Karga
Major Mayor Nagusi
Margin Faja guia Faxa gidaria
Marking Marcado Markaketa
Milling Fresado Fresaketa
Minor Menor Txiki
Nose radius Radio de punta Muturreko erradioa
Notching Entallado Hozkaketa
Oven Horno Labe
Overhang Voladizo Hegalkin
Overhead Gastos generales Gastu orokorrak
Packaging Empaquetado Paketeak egin
GLOSSARY

Pecking Picada Ziztada
Pin Punzn Puntzoi
Pitch Paso Neurri
Plunge Penetracin Barneratze
Powder Polvo Hauts
Power Potencia Potentzia
Pressing Prensado Prentsaketa
Profiling Perfilado Profilaketa
Radial cutting depth Profundidad de pasada radial / ancho de pasada Iraganaldi zabalera
Radii Radios Erradioak
Rake Desprendimiento Jaulkitze
Reaming Escariado Otxabuketa
Reject Rechazo Errefus
Relief face Cara de desahogo Lasaitasun aurpegia
Revolution Vuelta Bira
Roughing Desbaste Arbastaketa
Rubbing Bruido Txartaketa
Sawing Serrado Zerraketa
Scrap Residuo Hondakin
Seat Asiento Eserleku
Shank Mango Kirten
Shape Forma Forma / Itxura
Shaping Limado Karrakaketa
Sharp Afilado Zorrotz
Shearing Cizallamiento Ebakidura / Zizailadura
Shell end mill Fresa hueca Kofadun fresa
Shift Relevo Txanda / Errelebu
Shim Calza Altxagarri
GLOSSARY

Shoulder milling Escuadrado Eskuairaketa
Side Lateral / Secundario Albo/Bigarren
Sintering Sinterizado Sinterizazio
Skin Piel Azal
Slope Pendiente Malda
Solid tool Herramienta enteriza Pieza bakarreko erraminta
Spindle Cabezal Buru
Spindle speed Velocidad de giro Biraketa abiadura
Spray drying Secado por pulverizacin Lainoztatze bidezko lehorketa
Staff Personal Langilego
Stiffness Rigidez Zurruntasun
Strength Resistencia Erresistentzia
Stress Fatiga / Estrs Estres
Substrate Sustrato Substratu
Surface roughness Rugosidad superficial Gainazal zimurtasuna
Tapping Roscado con macho Ardatzarekin egindako hariztaketa
Thickness Espesor Lodiera
Tilting Inclinacin Inklinazio
Tip Punta Punta
Toolholder Portaherramientas Erraminta etxea
Torque Par Momentu
Toughness Tenacidad Zailtasun
Tray Bandeja Erretilu
Trochoidal Trocoidal Trokoidal
Turning Torneado Torneaketa
Unleaded Sin plomo Berunik gabeko
Up milling Contraposicin Kontrajartze
Wash away Limpiar Garbitu
GLOSSARY

Weak Debil Ahul
Wear Desgaste Higadura
Web Alma Arima
Wedge Cua Kua / Falka
Weight Peso Pisua
Wet Humedo Busti
Workpiece Pieza Pieza
Workshop Taller Tailer

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BACHELOR OF ENGINEERING

Mechanical and Manufacturing department

Mondragon Unibertsitatea - www.mondragon.edu

For bibliographic references, please refer to:

http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)

http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)

For videos, please refer to:

Cutting speed [m/min]

Solid tool Brazed insert Mechanically clamped insert

Turning RAKE FACE

MAJOR CLEARANCE (FLANK

Major (or side or lead) cutting edge angle

END MILLING CUTTERS PERIPHERAL AND FACE MILLING CUTTERS

High Speed Steel (HSS) Solid carbide drill

Point angle Point angle

Geometry for small

Main cutting edge

Tip cutting edge design

Insert material types

Rake angle Clearance angle

Side Rake angle Lead angle / Entering angle

Nose radius and Nose angle Chipbreaker

Groove type Obstruction type

Each insert has an

Nose radius Nose angle

VIDEO VIDEO VIDEO

Insert fabrication Powder fabrication VIDEO

Insert fabrication Pressing

Insert fabrication Sintering

Sintering duration: 8 hours

Insert fabrication Insert grinding

Higer and lower face Free profiling Profiling

Beveling, negative facet Peripheral

Insert fabrication Insert grinding

ER Treatment W/H proportion depends on

Insert fabrication Chemical Vapor Deposition (CVD) coating

Insert fabrication Physical vapor deposition (PVD) coating

- Thin coating thickness.

Insert fabrication Visual inspection, marking, packaging

1. Cutting Speed (Vc)

Vc: Cutting speed (m/min)

Dm: machined diameter (mm)

1. Cutting Speed (Vc)

Given the following parameters calculate

Cutting speed Vc = 120 m/min

DEFINITION: Relative movement between the workpiece and the tool.

3. Cutting depth (ap)

HIGH SPEED STEEL Threading 10 Thread pitch According to formula

HIGH SPEED STEEL Threading 15 Thread pitch According to formula

Surface finish depends on:

WIPER INSERTS: Advantages:

TOOL CENTRE HEIGHT

Diameters starting from > 10mm.

Spindle Speed Variation (SSV)

SSV technique may reduce or eliminate chatter.

1. Cutting Speed (Vc)

Vc 1000 Vc: Cutting speed (m/min)

DEFINITION: Relative movement between the workpiece and the tool.

fn = fzz z tooth number (flute number)

F = fnN = fzzN N spindle speed

Side milling A (5%-10%)

MILLING DIRECTION MILLING: Discontinuous cutting process

N rpm or rev/min Spindle speed N=(Vc1000)/()