ATMH1283 CNC and Workshop Technology

Milling Operation Calculation (Face Milling)

Milling
Face Milling
For Face Milling, consider the two possible cutting operations shown in Figure 1 below.

W = Width of workpiece
L = Length of workpiece
A = Approach distance Wc = Width of cut
Figure 1: Face Milling Operations

a) When the cutter is centered over a rectangular workpiece

The first operation is when the cutter is centered over a rectangular workpiece as in Figure
(1a).

The cutter feeds from right to left across the workpiece with length , L.

Case I: D > w

In order for the cutter to reach the full width of the workpiece, it must travel an approach
distance, A given by,

1
𝐴= (𝐷 − √𝐷2 − 𝑤 2 )
2
where,
A = Net approach distance
D = cutter diameter, mm
w = width of the workpiece, mm
ATMH1283 CNC and Workshop Technology
Milling Operation Calculation (Face Milling)

Figure Case I: Face Milling when D > w – Top View

Note: L = Length of the workpiece

A = A1 – A2

See Figure Case I:

1
𝐴1 = 𝐷
2
and,

1
𝐴2 = √𝐷2 − 𝑊 2
2
Hence,

1
𝐴= (𝐷 − √𝐷2 − 𝑤 2 )
2

Or, you can think figure it out this way:

The net travelling distance of the cutter (face milling tool) = L + A1 – A2
ATMH1283 CNC and Workshop Technology
Milling Operation Calculation (Face Milling)

Case II: D = w

When the diameter of the cutter is same with the width of the workpeice, i.e. D = W:

𝟏
The Approach Distance, 𝑨 = 𝑫
𝟐

The net travelling distance of the cutter (face milling tool) = L + A

ATMH1283 CNC and Workshop Technology
Milling Operation Calculation (Face Milling)

Case III: D < w

When the diameter of the cutter is smaller than the width of the workpeice, i.e. D < W.
Then, a SLOT is cut into the work,

𝟏
The Approach Distance, 𝑨 = 𝑫
𝟐

The net travelling distance of the cutter (face milling tool) = L + A

ATMH1283 CNC and Workshop Technology
Milling Operation Calculation (Face Milling)

b) When the cutter is offset to one side of the workpiece

When the cutter is offset to one side of the workpiece, as shown in Figure 1(b), in this case,
similar to the Slab Milling, the approach distance, A is given by:

𝐴 = √𝑊𝑐 (𝐷 − 𝑊𝑐 )

where,
D = cutter diameter, mm
Wc = width of the cut, mm

The Approach Distance, 𝑨 = √𝑾𝒄 (𝑫 − 𝑾𝒄 )

The net travelling distance of the cutter (face milling tool) = L + A

ATMH1283 CNC and Workshop Technology
Milling Operation Calculation (Face Milling)

Machining Time for Face Milling Operations

Machining Time, Tm

All the above

For either the operations above (Operation a or Operation b), the machining time is given by:

𝑁𝑒𝑡 𝑇𝑟𝑎𝑣𝑒𝑙𝑙𝑖𝑛𝑔 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒

𝑇𝑚 =
𝑓𝑟

Face Milling (similar to Slab Milling)

The cutting speed, v is determined at the outside diameter, D of a milling cutter. This can be
converted to spindle rotational speed, N using the same formula:
𝑣
𝑁=
𝜋𝐷
The feed f in milling is usually given as a feed per cutter tooth; called chip load, it represents the
size of the chip formed by each cutting edge. This can be converted to feed rate, fr by taking
into account the spindle speed, N and the number of teeth, nt on the cutter as follows:

𝑓𝑟 = 𝑁𝑛𝑡 𝑓

where,
feed rate = fr (mm/min)
N = spindle speed (rev/min)
Nt = number of teeth on the cutter
F = chip load (mm/teeth)

Material Removal Rate

Material Removal Rate in milling is determined using the product of the cross-sectional area of
the cut and feed rate. Accordingly, for a FACE-MILLING Operation, which to cut a workpiece
with width, w at a cutting depth, d, the material removal rate, RMR is:

𝑅𝑀𝑅 = 𝑤𝑑𝑓𝑟

This neglects the initial entry of the cutter before full engagement.
ATMH1283 CNC and Workshop Technology
Milling Operation Calculation (Face Milling)

Figure: Different types of Face Milling Operations