Metal Cutting Physics and Calculation of Speeds and Feeds

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Presentation transcript:

Metal Cutting Physics and Calculation of Speeds and Feeds

Variables that we control We have control over a few variables when machining: The contact velocity between the part and the cutting tool. This is the SPEED and is controlled by the RPM of the spindle. The rate at which the tool moves through the workpiece – the FEED RATE. The type of cutting tool (material, # cutting edges) The type and quantity of the coolant or lubricant

What we know Experimental about the machinability of materials is published. Machinery’s Handbook is a good reference. Suppliers of unusual alloys usually provide machinability data for their products. This data include: Recommended cutting tools and fluids Recommended cutting velocity and chip load (chip thickness)

Mechanics

Surface Velocity – Determining RPM Material properties of the workpiece and the cutting tool determine the maximum velocity at the cutting tool. The velocity and the RPM are related by CS = RPM * πD (1) RPM = CS / πD (2) For CS in FPM and D in inches RPM = 4 * CS / D (3)

Mills

Determining RPM - Examples Example cutting speeds with HSS tools: Aluminum 250 SFM Steel 25 SFM For a .25” dia. tool cutting aluminum RPM = 4 * CS/ D = 4 * 250 / .25 = 4,000 RPM For a 1” dia. tool cutting steel RPM = 4 * CS/ D = 4 * 25 / 1 = 100 RPM For a 1” dia. high speed insert cutting aluminum RPM = 4 * CS/ D = 4 * 9000 / 1 = 36,000 RPM

Feed Rate The optimum thickness of the chip formed by the cutting tool depends on the material properties of the workpiece and the cutting tool. Feed = RPM * T * N Feed =( inches/minute) T = chip thickness (inches) N = # cutting surfaces

Feed Rate Examples Typical chip loads: Aluminum .005”/tooth Steel .003”/tooth Turning steel on the lathe – 1” dia. workpiece RPM = 4 * CS/ D = 4 * 25 / 1 = 100 RPM Feed = RPM * T * N = 100 * .003 = 0.3 in/min High speed milling with 4 tooth 2” diameter cutter RPM = 4 * CS/ D = 4 * 9000 / 2 = 18,000 RPM FEED = RPM * T * N = 9000 * .005 * 4 = 180 in/min

Summary Find surface velocity and chip load data for your workpiece and cutting tool materials. Machinery’s Handbook is a good reference. Calculate RPM for your cutting tool diameter (mill) or workpiece diameter (lathe) Calculate feed rate using the chip load and # of cutting teeth.