MACHINE OPERATION CALCULATIONS

I. Turning

A. Machine Speed: To achieve a specific cutting speed:

N=

k*V * D1

N = machine speed in revolutions/minute (RPM) k is a constant to correct speed (V) and part diameter (D i ) units V is desired cutting speed, a Handbook Value D1 is largest part diameter (initial size) V given in surface feet per minute (SFPM), D1 in inches: k = 12 V given in meters per second (MPS), D1 in mm: k = 60000 V given in meters per minute (MPM), D1 in mm: k = 1000 If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k B. Cutting Time: minutes per operation CT is cutting time per pass L is length cut A is allowance or starting offset fr is machine feed rate units/revolution, a Handbook Value

CT =

(L + A) fr * N

C. Material Removal Rate (MRR or Q): Volume Removed cutting time

MRR =

* L (D12 - D22 )
4L fr N

D2 is Finished Diameter

MRR = k f r V [

D1 - D2 D1 + D2 ]* [ ] 2 2 D1 D1 - D2 [ ] t 2 D1 + D2 [ ] 1 2 D1

Substituting for N from above:

and:

t is Depth of cut (inch or mm)

MRR k V f r t
Therefore:

II. Boring

A. Machine Speed: as above except D1 is the finished (larger) diameter B. Cutting Time: same as above C: Material Removal Rate: as above except D1 is finished diameter while D2 is Initial (smaller) diameter. III. Facing, Slot Cutting or Cut Off

In facing, slot (plunge) cutting and cut off, the cutting speed for a given RPM decreases as the tool progresses toward the center of the piece being cut. This follows since most (manual) lathes cannot increase spindle speed (N) during cutting operations. Thus, the required N is calculated as above using the outside (largest) diameter of the part for a given V. A. Machine Speed
k* V * D1

N =

If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k

B. Cutting Time
(L + A) fr * N

CT =

C. Material Removal Rate (here D1 is Outside Diameter)

Vol.Removed D12 f r tN = CT 4*L
D1 2

MRR =

where: L is

for solids;

D1 - D i 2

for tubes

Di is inside diameter t is width of cut (tool) Substituting for N and L: MRR

k 2

f r tV

IV. Slab (Horizontal) Milling (be careful with units!!)

Terms Used: N: RPM of Cutter n: Number of Teeth on Cutter W: Width of cut (may be full cutter or partial cutter) t: depth of cut V: cutting speed -- a Handbook value L: Length of pass or cut fm: Table (machine) Feed ft: feed/tooth of cutter -- a Handbook value D: Cutter Diameter A. Cutting Speed:
kV D

N =

If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k B. Table Feed Rate:

f m = f t * N* n
C. Cutting Time:

CT =

L + LA fm

LA is Length of Approach of Tool to Work LA = t(D - t)

D. Material Removal Rate:

MRR = Vol. Removed L* W* t = = W* t* f m CT CT

Remember that the length of approach calculated here puts the cutter against the work at the start, we will add a small additional air gap to spin the tool to speed and allow the table to achieve target feed rate before chip making begins. When determining cutting time and MRR, care must be exercised. Ask yourself if total cutting time or time to make one pass across the part is being requested, ie. is a single or multiple pass operation to be studied. Also, note that in the MRR equation the cutting time term does not include the time of partial engagement (LA). Again, if a multi-pass operation is being employed, the appropriate width term should be used in the MRR equation.

V. Face (Vertical) Milling

Terms Used: N: RPM of Cutter n: Number of Teeth on Cutter W: Width of cut (may be full cutter or partial cutter) t: depth of cutter engagement V: cutting speed -- a Handbook value L: Length of pass or cut fm: Table (machine) Feed ft: feed/tooth of cutter -- a Handbook value D: Cutter Diameter LA: Approach Length LO: Length of OverTravel

A. Cutting Speed:
N = kV D

If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k B. Table Feed:

f m = f t * N* n

C. Cutting Time. Here several situation must be considered, these include: 1. Tool Not Fully Engaged with W<D/2 2. Tool not Fully Engaged but W> D/2 3. Tool Fully Engaged, Roughing Pass -- Doesnt require Full Wipe 4. Tool Fully Engaged, Finishing Pass -- requires Full Wiping Action
CT = (L+ LA + LO ) fm W(D - W)
D 2

1. LA = LO =

2. LA = LO = 3. LA =
D 2

LO = - 0.5* D 2 - W 2
D 2

4. LA = LO =

D: Metal Removal Rate:

Vol. Removed L* W* t = = W* t* f m CT CT

MRR =

Again, the cautions on single vs. multiple pass CT and MRR apply as with Slab Milling. Remember too, that the length of approach here puts the cutter against the work at the start, we will add a small additional air gap to spin the tool to speed and allow the table to achieve target feed rate before chip making begins. Also, care should be exercised with regards to units.

VI. Drilling

N =

kV D

A. Drill Speed, RPM

k is a Units Constant D is Drill Diameter V is cutting speed, a Handbook Value, if Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k B. Cutting Time (min)

CT =

(L + A) fr*N
D 2

A is allowance; usually f r is drill feedrate L is length of Hole

MRR =

Vol.Removed D2 Lf r N D2 f r N = = CT 4L 4

C. MRR is (again) Material Removal Rate And note, no material is removed while the Drill travels through the Allowance Zone Use caution with units!!