Speeds and Feeds

Computer Integrated Manufacturing © 2013 Project Lead The Way, Inc.

In This Lesson
• Identify common cutting tools
• Learn the definition of speeds and feeds
• Calculate cutting speeds and feed rate
 Basic Cutting Tools

Non-Center
Ball End
Center Cutting End
Mill
Cutting End Mill
Mill

Indexable
Shell Mill
Basic Cutting Tools

Combination
Drill & Countersink

Spotting Drill

Countersink
Flutes

2 Flute End Mill 4 Flute End Mill

• More cutting edges,
• More room for chip
longer tool life
evacuation
• Used for harder metals
• Used for light metals
• Clogs easily in deep
• Weak, short tool life
cuts
Center Vs. Non-Center Cutting

2 Flute 4 Flute 4 Flute

Center Center Non-Center
Cutting Cutting Cutting
Milling Tools
Tool Description Application

¼” 2 Flute HSS Facing, profiling,

Single End Mills pocketing,
for cutting slotting,
aluminum – 3/8 roughing, and
shank x 1 ¼ finishing
cutting length
¼” 2 Flute Ball Surfacing,
End Mill for slotting,
aluminum – 3/8 profiling,
shank x 1 ¾ roughing, and
cutting length finishing
Milling Tools
Tool Description Application

¼” Countersink Engraving, de-

& De-burring tool burring,
– 90 Degree countersink, spot
drilling
#3 Combined Spot drilling,
drill & engraving
countersink 90
degree
Milling Tools
Tool Description Application

¼” Spotting drill Spot drilling,

90 deg engraving
Cutting Tool Material Video
Definitions
• Cutting Speed – The rate of a tool
measured in surface feet per minute
• Spindle Speed – The number of
revolutions per minute (rpm) that is made
by the cutting tool of a machine
• Feed – The distance advanced by the
cutting tool along the length of the work for
every revolution of the spindle
Spindle Feeds Formula
• Defined in revolutions per minute (rpm)
• Found by dividing the cutting speed by the
circumference of the tool
CS
N=
C
C = circumference

CS  12 in.
N= ft
d
N = Spindle speed (rpm)
CS = Cutting speed (surface ft / min)
d = Diameter (in.) / rev
Recommended Cutting Speeds
Milling Speeds for High Speed Steel Tools
Material Cutting Speed in surface ft/min
Magnesium 300
Aluminum 250
Brass and Bronze 150
Copper 100
Cast Iron (Soft) 80
Cast Iron (Hard) 50
Mild Steel 90
Cast Steel 80
Alloy Steel (Hard) 40
Tool Steel 50
Stainless Steel 60
Titanium 50
High Manganese Steel 30
Note: Double Speed for Carbide Cutting Tools
 Example
What spindle speed should be used to
mill aluminum with a ½ inch end mill?
CS  12 in.
N= ft
d

250 ft  12 in.
N= min ft = 1,910 rpm
Cutting Speed for
Aluminum is 250
  0.5 in.
rev
surface ft/min
Your Turn
What spindle speed should be used to mill
Brass with a ¼ inch end mill?
CS  12 in.
N= ft
d

Cutting speed for soft cast iron is 150 surface ft/min

150 ft  12 in.
N= min ft = 2,293 rpm
  0.25 in.
rev
Calculating Feed Rates

fm = ft x nt x N
fm = Feed rate in.
min
ft = Feed in.
tooth  rev
nt = Number of teeth on the tool
N = Spindle speed = CS  12 in.
ft
d
Recommended Tool Feed
Tool Feed (in./tooth*rev)
Material Face Mill Side Mill End Mill
Magnesium .005-.020 .004-.010 .005-.010
Aluminum .005-.020 .004-.010 .005-.010
Brass and Bronze .004-.020 .004-.010 .005-.010
Copper .004-.010 .004-.007 .004-.008
Cast Iron (Soft) .004-.016 .004-.009 .004-.008
Cast Iron (Hard) .004-.010 .002-.006 .002-.006
Mild Steel .004-.010 .002-.007 .002-.010
Alloy Steel (Hard) .004-.010 .002-.007 .002-.006
Tool Steel .004-.008 .002-.006 .002-.006
Stainless Steel .004-.008 .002-.006 .002-.006
Titanium .004-.008 .002-.006 .002-.006
High Manganese Steel .004-.008 .002-.006 .002-.006
Note: Double Speed for Carbide Cutting Tools
Example Feed Rate
Calculate the feed rate for end milling aluminum
with a 2 flute, ½ inch HSS end mill.

fm = f t  nt  N
Tool Feed (in./tooth*rev)

ft=0.005 in.
tooth ● rev
Example Feed Rate
Calculate the feed rate for end milling aluminum
with a 2 flute, ½ inch HSS end mill.

CS  12 in. 250 ft  12 in.

N= ft = min ft = 1,910 rpm
d   0.5 in.
rev

fm = f t  n t  N ft=0.005 in. nt = 2 teeth

tooth  rev
fm = 0.005 in.  2 teeth  1,910 rpm
tooth  rev
fm = 19.1 in.
min
 Your Turn
Calculate the feed rate for face milling
aluminum with a 4 flute, ½ inch HSS end mill.

CS  12 in. 250 ft  12 in.

N= ft = min ft = 1,911 rpm
d   0.5 in.
rev
fm = f t  n t  N ft=0.005 in. nt = 4 teeth
tooth  rev
fm = 0.005 in.  4 teeth  1,911 rpm
tooth  rev
fm = 38.2 in.
min
Factors That Affect Feed Rates
• Power of spindle motor
• Condition of cutting tool
• Depth of cut
• Quality of surface finish required
• Roughing vs. finish cuts
• Condition of the machine
• Strength of fixture
Plunge Feed Rate
• Feed rate at which mill can plunge into
material
pfr = fm fm = ft  nt  N pfr = ft  nt  N
2
2
pfr = Plunge feed rate in.
min
fm = Feed rate in.
min
 Example Plunge Feed Rate
Calculate the plunge feed rate for plunging into
mild steel with a 4 flute, ½ inch HSS end mill.
Reference charts on next slides
CS  12 in. 90 ft  12 in.
N= ft min ft = 687 rpm
=
d   0.5 in.
rev
fm = ft  nt  N pfr = fm pfr = ft  nt  N
2 2
pfr = 0.002 in.  4 teeth  687 rpm
tooth  rev nt = 4 teeth
2
pfr = 2.7 in. ft = 0.002 in.
min tooth  rev
Recommended Cutting Speeds
Milling Speeds for High Speed Steel Tools
Material Cutting Speed in surface ft/min
Magnesium 300
Aluminum 250
Brass and Bronze 150
Copper 100
Cast Iron (Soft) 80
Cast Iron (Hard) 50
Mild Steel 90
Cast Steel 80
Alloy Steel (Hard) 40
Tool Steel 50
Stainless Steel 60
Titanium 50
High Manganese Steel 30
Note: Double Speed for Carbide Cutting Tools
Recommended Tool Feed
Tool Feed (in./tooth*rev)
Material Face Mill Side Mill End Mill
Magnesium .005-.020 .004-.010 .005-.010
Aluminum .005-.020 .004-.010 .005-.010
Brass and Bronze .004-.020 .004-.010 .005-.010
Copper .004-.010 .004-.007 .004-.008
Cast Iron (Soft) .004-.016 .004-.009 .004-.008
Cast Iron (Hard) .004-.010 .002-.006 .002-.006
Mild Steel .004-.010 .002-.007 .002-.010
Alloy Steel (Hard) .004-.010 .002-.007 .002-.006
Tool Steel .004-.008 .002-.006 .002-.006
Stainless Steel .004-.008 .002-.006 .002-.006
Titanium .004-.008 .002-.006 .002-.006
High Manganese Steel .004-.008 .002-.006 .002-.006
Note: Double Speed for Carbide Cutting Tools
 Now Your Turn
Calculate the plunge feed rate for plunging
copper with a 4 flute, ¼ inch HSS end mill.
CS  12 in. 100 ft  12 in.
N= ft min ft = 1,529 rpm
=
d   0.25 in.
rev
f m = f t  nt  N pfr = fm pfr = ft  nt  N
2 2
pfr = 0.004 in.  4 teeth  1,529 rpm
tooth  rev
2 nt = 4 teeth
pfr = 24.5 in.
min ft = 0.004 in.
tooth  rev
 Special Operations
CS  12 in./ft
N=
d
Other special operations require slower speeds:
Reaming – ½ to ⅔ of that used for drilling the material
Counterboring – ¼ of that used for drilling the material
Countersinking – ¼ of that used for drilling the material
Tapping (threading) – Determined by many factors
(usually range from 50 to 300 rpm)
References
Black, J., Kohser R. (2008). DeGarmo’s materials and
processes in manufacturing (10th ed.). Danvers,
MA: John Wiley & Sons, Inc.
Kibbe, R.R., Neely, J.E., Meyer, R.O., & White, W.T.
(2002). Machine tool practices. Upper Saddle River, NJ:
Prentice Hall.
Oberg, E., Jones F. D., Horton, H. L., & Ryffell, H. H.
(2000). Machinery’s handbook (26th ed.). New York, NY:
Industrial Press Inc.