Example for calculation on Milling

An end milling process is to be done on a low carbon steel using uncoated carbide. The cutting
tool has 5 helical teeth. The length of cut is 100 mm and the cutter diameter is 8 mm. The cut is
done in a single pass. Determine:

a) Feed, f:

b) Speed, V:

c) Depth of cut, d:

d) Spindle speed, N

e) Linear feed, v

f) Material Removal Rate, MRR

g) Power requirements, P

h) Cutting time, t

Solution

a) f = 0.13 mm / rev
b) V = 120 m / min
c) d =1
d) Spindle speed, N
V=πDN
 V 120 m / min
N= = = 4775 rpm
πD π (8mm ) 1m
1000 mm

e) Linear feed, v

v = fNn = 0.13 mm / tooth ( 4775 rpm )( 5) = 3104 mm / min

f) Material Removal Rate, MRR

MRR = w d v = (8mm )(1mm )( 3104 )mm / min = 24830 mm 3 / min

g) Power requirements, P

P=ut x MRR
W .s
P = ut MRR = 2 24830 mm 3 / min( 1 / 60 )(1 / 1000 ) = 0.87 kw
mm 3

h) Cutting time, t
t= ( l + 2lc ) / v where lc = Dd
lc = Dd = 8(1) = 2.828

t = ((100 + 2( 2.82 )) mm / 3104 mm / min = 2.04 s

Example
A slab milling operation is being carried out on a 0.3mm long, 0.1m wide annealed mild
steel block at a feed f = 0.25 mm / tooth and a depth of cut d =3.13 mm . the cutter
diameter D =50 mm in diameter, has 20 straight teeth, rotates at N =100 rpm , and by
definition is wider that the block to be machined. Calculate the material removal rate,
estimate the power and torque required for this operation, and calculate the cutting time.
Solutions
Form the information given, the linear speed of the workpiece, v , can be calculated :
v = fNn = (0.25 )(100 )( 20 ) = 500 mm / min

The material removal rate is calculated to be:

MRR = wdv = (100 )( 3.13 )( 500 ) =156 ,500 mm 3 / min =156 .5cm 3 / min

Since the workpiece is annealed mild steel, let’s estimate unit power form table 21.2 as
3W.s/mm3. Hence, the power required can be estimated as:
 1
P = u t MRR = (3)(156 ,500 )( ) = 7.82 KW
60
The torque acting on the cutter spindle also can be calculated by noting that power is the
product of torque and the spindle rotational speed 9in radians per unit time). Therefore,
Power
Torque =
Rotational speed

(7820 )( 60 N − m / min .W )
= = 747 Nm
(100 rpm ) 2π

The cutting time is given by:

t = (l + l c ) / v

Where the quantity l c can be shown, form simple geometric relationships and for
D >> d , to approximate
lc = Dd = (50 )( 31 .3) =12 .5mm

Thus, the cutting time is:

300 + 12 .5
t= = 0.625 min = 37 .5 s
500