Cutting Speed, Feed, and Depth of Cut

Session 13

Efficiency of a Milling Operation

Cutting speed
Too slow, time wasted Too fast, time lost in replacing/regrinding cutters

Feed
Too slow, time wasted and cutter chatter Too fast, cutter teeth can be broken

Depth of cut
Several shallow cuts wastes time
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Cutting Speed
Speed, in surface feet per minute sfm or meters per minute smm at which metal may be machined efficiently Work machined in a lathe, speed in specific number of revolutions per min (r/min) depending on its diameter to achieve proper cutting speed In milling machine, cutter revolves r/min depending on diameter for cutting speed
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Important Factors in Determining Cutting Speed

Type of workpiece material Cutting tool material Diameter of cutter Surface finish required Depth of cut taken Rigidity of machine and work setup
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Milling Machine Cutting Speeds

High-Speed Steel Cutter Carbide Cutter

Material
Alloy steel Aluminum

ft/min
4070

m/min
1220

ft/min
150250

m/min
4575

5001000 150300 10002000 300600

Bronze
Cast iron

65120
5080

2035
1525 3045

200400
125200 400600

60120
4060 120180

Free m steel 100150

Mach steel
Tool steel

70100
6070

2130
1025 1820

150250
100300 125200

4575
3090 4060
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Stnless steel 3080

Inch Calculations
For optimum use from cutter, proper speed must be determined Diameter of cutter affects this speed
Calculate speed required to revolve a 3-in. diameter high-speed steel milling cutter for cutting machine steel (90 sf/min). simplify formula CS(ft ) 90 12 xCS 4 xCS r / min circumfere nce(in .) 3x3.1416 3x3.1416 D

4 x 90 360 r / min 120 3 3

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Metric Calculations
Formula for r/min of the milling machine using metric measurement
simplify formula

CS( m)x1000 CSx 1000 CS( m)x320 r / min x D(mm) 3.1416 x D D( mm )

Calculate the r/min required for a 75 mm diameter high-speed steel milling cutter when cutting machine steel (CS 30 m/min)

30 x320 9600 r / min 128 75 75

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Cutting Speed Rules for Best Results

1. For longer cutter life, use lower CS in recommended range 2. Know hardness of material to be machined 3. When starting, use lower range of CS and gradually increase to higher range 4. Reduce feed instead of increase cutter speed for fine finish 5. Use of coolant will generally produce better finish and lengthen life of cutter
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Milling Machine Feed

Distance in inches (or mm) per minute that work moves into cutter
Independent of spindle speed

Feed: rate work moves into revolving cutter

Measured in in/min or mm/min

Milling feed: determined by multiplying chip size (chip per tooth) desired, number of teeth in cutter, and r/min of cutter Chip, or feed, per tooth (CPT or FPT): amount of material that should be removed by each tooth of the cutter
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Factors in Feed Rate

1. 2. 3. 4. 5. 6. 7. Depth and width of cut Design or type of cutter Sharpness of cutter Workpiece material Strength and uniformity of workpiece Type of finish and accuracy required Power and rigidity of machine, holding device and tooling setup
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Recommended Feed Per Tooth - HSS

Sample TableFace See Table 60.2 in Mills Text Material in. Helical Mills mm Slotting and Side Mills in. mm

mm in. 0.55

Alloy steel
Aluminum

.006
.022

0.15 .005

0.12
.018 0.45

.004
.013

0.1
0.33

Brass and bronze (medium) Table shows .014 feed 0.35 per tooth .011 .008 0.2 for0.28 roughing cuts Cast iron for finishing cut, the feed per tooth would be (medium) reduced .013 to1/2 0.33 .010 .007 0.18 or even 1/3 of0.25 value shown
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Recommended Feed Per Tooth Cemented Carbide

Sample Table See Table 60.3 inFace Text Mills Helical Mills Slotting and Side Mills

Material
Aluminum

in.
.020

mm

in. mm

in.
.012

mm
0.3

0.5 .016 0.40

Brass and bronze (medium) .012 0.3 .010 0.25 .007 0.18 Cast iron Table shows feed per tooth for roughing cuts for finishing cut, the feed tooth0.25 would be (medium) .016 0.4 .013 0.33 per .010 reduced to1/2 or even 1/3 of value shown
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Ideal Rate of Feed

Work advances into cutter, each successive tooth advances into work equal amount
Produces chips of equal thickness
Feed per tooth

F = no. of cutter teeth x feed/tooth x cutter r/min

Feed (in./min) = N x CPT x r/min

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Feed Calculations
Inch Calculations Find the feed in inches per minute using a 3.5 in. diameter, 12 tooth helical cutter to cut machine steel (CS80)
First, calculate proper r/min for cutter:
r / min 4 x CS 4 x 80 91 D 3.5

Feed(in/min) = N x CPT x r/min =12 x .010 x 91 = 10.9 or 11 in/min

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Feed Calculations
Metric Calculations
Calculate the feed in millimeters per minute for a 75-mm diameter, six-tooth helical carbide milling cutter when machining cast-iron (CS 60) First, calculate proper r/min for cutter:
r / min CS x 320 60 x 320 19,200 256 D 755 75

Feed(in/min) = N x CPT x r/min = 6 x .025 x 256 = 384 mm/min

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Direction of Feed: Conventional

Most common method is to feed work against rotation direction of cutter
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Direction of Feed: Climbing

When cutter and workpiece going in same direction Machine equipped with backlash eliminator can increase cutter life up to 50%
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Advantages of Climb Milling

Increased tool life (up to 50%)
Chips pile up behind or to left of cutter

Less costly fixtures required

Forces workpiece down so simpler holding devices required

Improved surface finishes

Chips less likely to be carried into workpiece
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Advantages of Climb Milling

Less edge breakout
Thickness of chip tends to get smaller as nears edge of workpiece, less chance of breaking

Easier chip removal

Chips fall behind cutter

Lower power requirements

Cutter with higher rake angle can be used so approximately 20% less power required
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Disadvantages of Climb Milling

Method cannot be used unless machine has backlash eliminator and table gibs tightened
Cannot be used for machining castings or hot-rolled steel
Hard outer scale will damage cutter

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Depth of Cut
Roughing cuts should be deep
Feed heavy as the work and machine will permit May be taken with helical cutters having fewer teeth

Finishing cuts should be light with finer feed

Depth of cut at least .015 inch Feed should be reduced rather than cutter speeded up

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