Drilling Machines - Cutting Speeds & RPM Calculations

Tools used in drilling operations represent nearly 25% of all the tools being used in the
world. There are those operations that are strictly drilling operations, but we also use
drilling machines to perform other operations such as reaming, tapping, countersinking
and counterboring. The rules and principles of cutting speeds and RPM calculations
apply to all of the operations being performed on drilling machines. An example of this
would be reaming. Reaming is done at half the speed and twice the feed as drilling. This
rule still applies on the drill press as it does on the milling machine or the lathe. Pay very
close attention to the information introduced in this unit and other units dealing with
cutting speeds because cutting speeds have the greatest impact on tool life.

Cutting Speed  

Cutting speed is the speed at the outside edge of the tool as it is cutting. This is also
known as surface speed. Surface speed, surface footage, and surface area are all directly
related. If two tools of different sizes are turning at the same revolutions per minute
(RPM), the larger tool has a greater surface speed. Surface speed is measured in surface
feet per minute (SFPM). All cutting tools work on the surface footage principle. Cutting
speeds depend primarily on the kind of material you are cutting and the kind of cutting
tool you are using. The hardness of the work material has a great deal to do with the
recommended cutting speed. The harder the work material, the slower the cutting speed.
The softer the work material, the faster the recommended cutting speed (Figure 1).

Steel
Alumi
Iron Lead
num

Increasing Cutting Speed

Figure 1

The hardness of the cutting tool material will also have a great deal to do with the
recommended cutting speed. The harder the drill, the faster the cutting speed (Figure 2).
The softer the drill, the slower the recommended cutting speed.

Carbon Steel
High Speed
Carbide
Steel

Increasing Cutting Speed

Figure 2

The three factors, cutting speed, feedrate and depth of cut, are known as cutting
conditions. Cutting conditions are determined by the machinability rating of the material.
Machinability is the comparing of materials on their ability to be machined. From
machinability ratings we can derive recommended cutting speeds. Recommended cutting
speeds are given in charts. These charts can be found in the Machinery’s Handbook,
textbook, or a chart given to you by your tool salesperson. In Table 3 you will find a
typical recommended cutting speed chart for drilling.

Table 3 Recommended Cutting Speeds for Drilling with High-Speed Steel Drills
For reamers, use 1/2 to 2/3 speed given in this table.

Material Hardness, Cutting Material Hardness, Cutting

Bhn Speed, Bhn Speed,
fpm fpm

Plain Carbon Steels

AISI–1019, 1020, 1030, Stainless Steels
1040, 1050, 1060, 1070, 120-150 80–120 (Cont.) 225–275 60–90
1080, 1090 150–170 70–90 Cold-Drawn 135–185 100–120
170–190 60–80 Ferritic
190–220 50–70 Martensitic 135–185 100–130
220–280 40–50 Annealed 185–240 90–120
280–350 30–40 Cold-Drawn 275–325 50–60
350–425 15–30 Quenched & 375–425 30–40
Alloy Steels Tempered
AISI-1320, 2317, 2515,
3120, 3316, 4012, 4020, 125–175 60–80 150–250 70–80
4120, 4128, 4320, 4620, 175–225 50–70 Tool Steels 200–250 20–40
4720, 4820, 5020, 5120, 225–275 45–60 Water Hardening 175–225 40–50
6120, 6325, 6415, 8620, 275–325 35–55 Cold Work 100–150 60–70
8720, 9315 325–375 30–40 Shock Resisting 150–200 50–60
375–425 15–30 Mold 200–250 30–40
Alloy Steels 250-275 15–30
AISI-1330, 1340, 2330, High-Speed Steel
2340, 3130, 3140, 3150, 175–225 50–70 110–140 90–140
4030, 4063, 4130, 4140, 225–275 40–60 Gray Cast-Iron 150–190 80–100
4150, 4340, 4640, 5130, 275–325 30–50 190–220 60–80
5140, 5160, 52100, 325–375 25–40 220–260 50–70
6150,
6180, 6240, 6290, 6340, 375–425 15–30 260–320 30–40
6380, 8640, 8660, 8740,
9260, 9445, 9840, 9850

Stainless Steels 110–160 120–140

Standard Grades Malleable Iron 160–200 90–110
Austenitic Ferritic 200–240 60–90
Annealed Pearlitic 240–280 50–60
Cold-Drawn 135–185 40–50
Ferritic 225–275 30–40
Martensitic 135–185 50–60 200–300
Annealed Aluminum Alloys 150–250
135–175 55–70 Cast-Nonheat Treated 150–300
Quenched & Tempered 175–225 50–60 Cast-Heat Treated 140–300
275–325 30–40 Wrought-Cold Drawn
Free Machining Grades 375–425 15–30 Wrought-Heat Treated
Austenitic 150–300
Annealed Brass & Bronze
135–185 80–100 (Ordinary) 30–100

Bronze (High
Strength)

The spindle speed must be set so that the tool will be operating at the correct cutting
speed. To set the proper spindle speed, we need to calculate the proper revolution per
minute or RPM setting. We stated earlier that cutting speed or surface speed would
change with the size of the tool. So to keep the surface speed the same for each size tool,
we must use a formula, which includes the size of the tool, to calculate the proper RPM
to maintain the proper surface footage.

Calculating RPM for Drilling Top

The RPM setting for drilling depends on the cutting speed of the material and the size of
the drill bit. The RPM setting will change with the size of the bit. As the drill bit gets
smaller, the RPM must increase to maintain the recommended surface footage. Take the
case of the wheel. Think of the drill bit as a wheel and the cutting speed as a distance. A
larger wheel (drill bit) will need to turn less revolutions to cover the same distance in the
same amount of time than a smaller wheel (drill bit). Therefore, to maintain the
recommended cutting speed, larger drills must be run at slower speeds than smaller drills.

The drill press must be set so that the drill bit will be operating at the proper surface
speed. Spindle speed settings on the drill press are done in RPMs. To calculate the proper
RPM for the tool, we must use the following formula:
 Cutting speed (CS) X 4
Diameter of cutter (D)
This simplified version of the RPM formula is the most common formula used in
machine shops. This RPM formula can be used for other machining operations as well.

Let's put this formula to work in calculating the RPM for the drilling example below. Use
the recommended cutting speed charts in Table 3.

A 0.50 drill is being used to drill a piece of 1018 steel with a brinnel hardness of 200.
Calculate the RPM setting to perform this drilling operation.

Cutting Speed = 70 (fpm)

Diameter of Cutter = 0.500

Although you have calculated the RPM, remember that this is only a recommendation.
Some judgment must be made in selecting the actual R.P.M. setting to use. There are
always outside factors that must go into deciding on the proper speed and feed to use.
Ask yourself these questions before deciding on an R.P.M. setting. How sturdy is my
setup? Go slower for setups, which lack a great deal of rigidity. Am I using coolant? You
may be able to use a faster speed if you are using flood coolant. How deep am I drilling?
If you’re drilling a deep hole, there is no place for the heat to go. You may have to slow
the RPM down for deep whole drilling.

The greatest indicator of proper and improper cutting speed is the color of the chip. When
using a high-speed steel drill bit, the chips should never be turning brown or blue. Straw-
colored chips indicate that you are on the maximum edge of the cutting speed for your
cutting conditions. When using carbide, chip colors can range from amber to blue, but
never black. A dark purple color will indicate that you are on the maximum edge of your

cutting conditions. Carbide cutting tools are covered in much greater detail in another
section of your learning materials.

Let’s try some more examples.

A 1.00-inch, high-speed steel (HSS) drill is being used on a piece of 1045 steel with a
brinnel hardness of 300. Calculate the RPM setting to perform this cutting operation.
Cutting Speed = 50 (fpm)
Diameter of Cutter = 1.00

A 3/4-inch (HSS) drill is used on a piece of (leaded) 11L17 steel with a brinnel hardness
of 100. Calculate the RPM setting to perform this drilling operation.

Cutting Speed = 130 (fpm)

Diameter of Cutter = 0.75

Calculating RPM for Reaming

The drill press RPM setting for reaming depends on the cutting speed of the material and
the size of the ream. The RPM setting will change with the size of the ream. As the ream
gets smaller, the RPM must increase to maintain the recommended surface footage.
Although you will find specific cutting speeds for reaming, a simple rule of half the speed
will work for most reaming operations. Using half the spindle speed you calculated for
the drilling operation is a commonly accepted method for determining the reaming speed
in most machine shops.

Let’s try an example.

A high speed steel "G" drill is being used prior to reaming a 3/8 hole on a piece of 1095
steel with a brinnel hardness of 300. Calculate the RPM setting to perform the drilling
and reaming operations.

Cutting Speed = 40 (fpm)

Diameter of Cutter = 0.3701 (G drill)

Half the speed for reaming would be = 432 / 2 = 216 RPM for reaming.
Calculating RPM for Countersinking and Counterboring Top

The drill press RPM setting for countersinking and counterboring also depends on the
cutting speed of the material and the size of the tool. The RPM setting will change with
the size of the tool. As the cutting tool gets smaller, the RPM must increase to maintain
the recommended surface footage. Although you will find specific cutting speeds for
countersinking and counterboring, a simple rule of 1/3 the speed of a drill of the same
size will work for most countersinking and counterboring operations. The RPM for a
counterbore would be fairly simple to calculate using the 1/3 method, but calculating the
RPM for a countersink brings about a different set of circumstances. The countersink is
tapered (Figure 4).

As you can see from the figure, the

RPM setting would be slower for a
countersink being cut at diameter
"B," than for a countersink being cut
Figure 4 at diameter "A".
 

The part prints will usually

state the finished diameter
of the countersink (Figure
5).  Use this as the
diameter for calculating
the spindle speed setting.
Otherwise, use an
approximate size and
watch your chip color
carefully.

Figure 5
Let’s try an example.

Let’s calculate the RPM for the countersink in Figure 5. The material is 1045 steel with a
brinnel hardness (bhn) of 200.

Cutting Speed = 75(fpm)

Diameter of Cutter = 0.38 for a 0.38 drill

One-third the speed for countersinking would be = 789/ 3 = 263 RPM.

Center Drill RPM Calculations 

A center drill or combination drill and countersink (Figure 6) is used for spotting holes in
workpieces or for making center holes for turning work. Center drills, as you can see
from the illustration, are short and sturdy and will not bend or flex under pressure. When
calculating the proper RPM for using a center drill, use the diameter of the pilot for your
calculations. Center drills will break if they are run too slowly. Using the smaller
diameter of the center drill will assure that the RPM setting is sufficient. If you find that
the drill chatters as you reach the proper depth, slightly decrease the RPM setting.

Figure 6

Let’s try an example.

Lets calculate the RPM for the center drilling 1018 steel with brinnel hardness (bhn) of
100. A #4 center drill with a pilot drill diameter of 1/8 inch will be used.

Cutting Speed = 100(fpm)

Diameter of Cutter = 0.125
RPM Calculation for Threading Top

Selecting the best RPM for power tapping can be very complicated. There are many
variables that must be taken into consideration when selecting the best spindle speed for
machine tapping. Among the variables are:

A. Material to be tapped. Cutting speeds need to decrease with the hardness of the
material.
B. Length of the hole. The deeper the hole the slower the RPM.
C. Size of the chamfer on the tap. Taps with long chamfer tapping short holes can be
run faster. However, taps with long chamfers tapping long holes must be run
slower.
D. Pitch of the thread. Coarse taps need to be run slower than fine taps.
E. Percentage of full thread. The higher the percentage of full threads the slower the
RPM.
F. Type and amount of cutting fluid. The greater the amount of cutting fluid getting
to the tap the faster the RPM.
G. Surface treatment of the tap. A tap that has been nitride or oxide coated can be run
much faster than a tap, with no coating.
H. Type of tap. Spiral-fluted and spiral-pointed taps can operate at higher cutting
speeds than can straight-fluted taps.

The RPM formula for tapping is no different from the other formula we have been using,
but the consideration mentioned for tapping must be made before we actually do any
power tapping. Until you know how the tap will operate under your conditions, start with
1/3 to 1/2 the calculated RPM and gradually increase the RPM to the capacity of the
conditions. A table of recommended cutting speeds for threading is included in Table 7.

Table 7   Cutting Speeds for Machine Tapping

Material Cutting Material Cutting

Speed, fpm Speed, fpm

Aluminum
Low Carbon Steels 50 to 200
Up to .25% C 40 to 80 Brass
50 to 200
Medium Carbon Steels Manganese Bronze
.30 to .60% C 30 to 60
Annealed 30 to 60
Heat Treated Phosphor Bronze 30 to 60
(220 to 280 Bhn) 20 to 50
Naval Brass 80 to 100
Tool Steels, High Carbon
and High-Speed Steel 20 to 40 Monel Metal 20 to 40

Stainless Steels 5 to 35 80 to 100

Tobin Bronze
Gray Cast-Iron 40 to 100
Plastics 50 to 100
Malleable Iron Thermoplastics 50 to 100
Ferritic 80 to 120 Thermosetting
Pearlitic 40 to  80 50 to 100
Hard Rubber
Zinc Die Castings 60 to 150 50 to 100
Bakelite

Let’s try an example.

Let’s calculate the RPM for tapping a 1/2-13 UNC hole. The material is 1018 steel with a
brinnel hardness (bhn) of 100.

Cutting Speed = 50 fpm

Diameter of Cutter = 0.50 for a 1/2 tap