Cutting Conditions

Milling Ex

03 Cutting Conditions – MILLING EX.PDF

Oscar Olvera
 Milling
Exercise 01

A component (material: steel 1018, hardness: 120 Bhn) with the following dimensions: width 60 mm
and length 200 mm, is going to be face milled to remove a layer 4 mm thick. Determine the cutting
conditions and machining time for each of the tools used:

Spindle speed, rpm

Feedrate, mm/min
Machining time, sec

a) Tool 1: Diameter 100 mm, Coated carbide, 8 teeth

b) Tool 2: Diameter 100 mm, Coated carbide, 4 teeth
c) Tool 3: Diameter 100 mm, High Speed Steel (HSS), 4 teeth.
 Milling
Exercise 02

A square shoulder is going to be face milled on a block of steel 1045, 180 Bhn, with a depth of cut 4
mm and a width of cut of 10 mm, using a 100 mm diameter tool with 6 coated carbide teeth. The
length of the block is 120 mm.

Determine the cutting conditions and machining time for the operation:

• Cutting velocity, m/min

• Spindle speed, rpm
• Feedrate, mm/min
• Machining time, sec
 Milling

Exercise 03

A slot (depth = 4 mm, width=12 mm) is going to be face milled on a block of steel 1045, 230
Bhn, in one cutting pass. A 12 mm diameter HSS endmill, with 4 teeth will be used for the
operation. The length of the block is 60 mm.

Determine the cutting conditions and machining time for the operation:

• Cutting velocity, m/min

• Spindle speed, rpm
• Feedrate, mm/min
• Machining time, sec
 Milling
Exercise 4

The top surface of a rectangular block (steel 1040, 250 BHN) is face milled with a depth of cut of 1 mm. The
part is 210 mm width and 300 mm length. A 76 mm diameter coated carbide cutter with 8 teeth is used. For
each cutting pass only 75% of the diameter is engaged. A gap of 3 mm is left at entry and exit of the cutter.

Determine the cutting conditions and machining time of the operation:

• Spindle speed, rpm

• Feedrate, mm/min
• Machining time, sec

10
 Milling
Exercise 4
3

0.75D
210

300

11
 Milling
Exercise 5

The top surface of a workpiece (steel 1045, 250 BHN) is face milled with a depth of cut of 1 mm.
The dimensions of the component are as shown in the drawing. A 50 mm diameter coated
carbide cutter with 8 teeth is used. For each cutting pass only 75% of the diameter is engaged. A
gap of 3 mm is left at entry and exit of the cutter.

Determine the cutting conditions and machining time of the operation:

• Spindle speed, rpm

• Feedrate, mm/min
• Machining time, sec

14
Exercise 5 Milling
R50

250
R50
400
15
 Milling
Exercise 6

A component (material: steel 1045, hardness: 200 Bhn) with the following dimensions: width 50 mm,
length 80 mm, is to be face milled. Two passes will be made, a roughing and a finishing pass. The depths
of cut to be used for each pass are:

• Roughing – 4 mm
• Finishing – 1 mm .

Tools:
a) Coated Carbide tool, 75 mm diameter, 4 teeth.
b) High Speed Steel tool, 75 mm diameter, 4 teeth.

For each of the tools, determine the cutting conditions to be used for each cutting pass (roughing and
finishing):

• Spindle Speed, rpm

• Feedrate, mm/min
• Machining time, sec
22