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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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Material
Alloy steel Aluminum
ft/min
4070
m/min
1220
ft/min
150250
m/min
4575
Bronze
Cast iron
65120
5080
2035
1525 3045
200400
125200 400600
60120
4060 120180
Mach steel
Tool steel
70100
6070
2130
1025 1820
150250
100300 125200
4575
3090 4060
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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
Metric Calculations
Formula for r/min of the milling machine using metric measurement
simplify formula
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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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 feed per tooth for0.28 .008 0.2 .014 0.35 .011 roughing cuts Cast iron for finishing cut, the feed per tooth would be (medium) reduced to1/2 or even 1/3 of0.25 shown 0.18 .013 0.33 .010 value .007
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Material
Aluminum
in.
.020
mm
in. mm
in.
.012
mm
0.3
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 per tooth0.25 be (medium) .016 0.4 .013 0.33 .010 would reduced to1/2 or even 1/3 of value shown
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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 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
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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
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