Machinist

[Lawrence London <lfljvenaura@gmail.com>]

F&D Tool - Carbide & High Speed Cutting Tools
http://www.fdtool.com/cubecart/index.php?_a=speeds

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SPEEDS & FEEDS

FEEDS & SPEEDS FOR MILLING CUTTERS

The proper selection of feeds and speeds is the most important factor in the economical application of any cutting tool.

Speed is generally known as the rate of peripheral speed in terms of surface feet per minute (SFM). SFM is usually converted to revolutions per minute as shown in formula Table 1.

Feed is generally shown as feed in inches per revolution or as feed per tooth in inches (FPT).

The initial choise of feeds or speeds will be at the lower of high values of the ranges listed depending upon the following variables.

FEED
Use lower feed range for: Saws, End Mills, and Form Cutters Fine tooth cutters Frail and small cutters Light and finishing cuts Deep slots Hard to machine materials Frail set-ups	Use higher feed range for: Face and Slab milling Coarse tooth cutters Rugged cutters Heavy roughing cuts Abrasive materials East to machine materials Rigid set-ups

SPEED
Use lower feed range for: Heavy cuts Hard materials Tough materials Abrasive materials Maximum cutter life Minimum tool wear	Use higher feed range for: Light cuts Softer materials Non-metallics Frail work piece or set-up Maximum production rates Better finishes Hand feed operations Higher rakes (HSS cutters)

FEED, SPEED, AND HORSEPOWER CALCULATIONS

Modern milling cutters capable of operation at higher feeds and speeds, and removing more cubic inches of metal per minute, require greater machine rigidity and more power. Therefore it is important to ascertain that sufficient power is available to handle the desired depth and width of cut at the higher feeds and speeds.

The following formulae are suggested for the calculation on feeds and speeds plus horespower requirements.

T = Number of teeth in cutter D = Cutter Diameter in inches RPM = Revolutions pet minute SFM = Surface feet per minute F = Feed in inches per minute

f = Feed per tooth in inches W = Width of cut d = Depth of cut HP = Motor Horsepower C = Machinability constant*

*Machinability constant values for various materials are based on removing one cubic inch of metal per minute per horsepower with 60% power efficiency at the spindle nose and a 25% allowance for cutter dulling.

Aluming, Magnesium, Dural Brass Soft Bronze, Copper Cast Iron Steel up to 150 Brinell, Malleable Iron Steel, 300 Brinell, Hard Bronze Steel, 400 Brinell

4.0 plus 2.5 2.0 1.5 .75 .6 .5

TABLE 1

.	SPEED		FEED
TYPE OF MATERIAL	HSS	CARBIDE	HSS	CARBIDE
Aluminum, Magnesium Brass & Bronze - Soft Brass & Bronze - Hard Copper Cast Iron - Soft Cast Iron - Hard	600 & Up 250 - 300 150 - 200 150 - 200 75 - 100 50 - 75	1000 & Up 1000 & Up 400 1000 & Up 250 - 350 200 - 250	.005-.025 .005-.020 .003-.010 .005-.015 .005-.015 .003-.008	.005-.030 .010-.020 .005-.010 .005-.015 .010-.022 .005-.010
Steel
100 Brinell 200 Brinell 300 Brinell	125 - 175 70 - 90 40 - 50	450 - 600 350 - 450 200 - 250	.004-.010 .004-.010 .003-.005	.005-.020 .005-.010 .005-.010
Stainless Steel
Hard Others	35 - 70 70 - 105	250 - 400 250 - 400	.003-.005 .003-.005	.003-.012 .003-.012
Titanium
Under 100,000 PSI 100,000 to 135,000 PSI 1,350 PSI & Over	35 - 55 25 - 35 15 - 25	150 - 180 120 - 150 80 - 120	.003-.005 .002-.005 .001-.005	.004-.008 .003-.008 .002-.008
High Temperature Alloys
Ferritic Low Alloys Austenitic Alloys Nickel Base Alloys Cobalt Base Alloys	40 - 60 20 - 30 5 - 20 5 - 10	150 - 300 100 - 235 50 - 150 50 - 100	.002-.005 .001-.004 .001-.003 .001-.003	.003-.008 .002-.006 .002-.006 .002-.006
High Temperature Alloys
180,000 - 220,000 PSI 220,000 - 260,000 PSI 260,000 - 300,000 PSI	25 - 40 10 - 25 6 - 10	120 - 150 80 - 120 50 - 100	.002-.005 .001-.005 .001-.003	.003-.008 .002-.008 .002-.006

The selction of initial feed within each range will vary with the type of operation. The following is an example of the starting feed for HSS Cutters in mild steel.

Type of Cut	Starting Feed per Tooth
Face Milling Straddle Milling Channel or Slot Milling Slab Milling Sawing	.008 .008 .008 .007 .002

Feeds for End Mills will vary between .0002 and .003 feed per tooth depending upon the size, material and depth of cut. End Mills are unsupported on the cutting edge and will deflect under heavy chip loads. The amount of deflection permitted will determine the "feed per tooth" selected. It should be noted, however, that a thick chip is desirable as a very fine feed can cause rapid cutting edge wear.
Starting speeds and feeds for "Ruffer" end mills should be the same as for standard end mills. However, because of their lower cutting forces and chatter-free operation, the table feed can often be increased up to 2 or 3 times greater than that used for standard end mills.

TABLE OF CUTTING SPEEDS

http://www.fdtool.com/cubecart/cutterdata.html

Surface Feet per Minute
	15'	20'	25'	30'	35'	40'	45'	50'	60'	70'	80'	90'	100'	110'	120'	130'	140'
Diameter in inches	Revolutions per Minute																	Diameter in inches
1/64	3667	4890	6112	7334	8559	9779	11002	12224	14669	17114	19558	22003	24448	26893	29338	31782	34227	1/64
1/32	1834	2445	3056	3667	4278	4890	5501	6112	7334	8557	9779	11002	12224	13446	14669	15891	17114	1/32
3/64	1222	1630	2037	2445	2852	3260	3667	4075	4890	5705	6519	7334	8149	8964	9779	10594	11409	3/64
1/16	917	1222	1528	1833	2139	2445	2750	3056	3667	4278	4889	5500	6112	6723	7333	7945	8556	1/16
3/32	611	815	1019	1222	1426	1630	1834	2037	244	2852	3260	3667	4075	4482	4890	5297	5705	3/32
1/8	458	611	764	917	1070	1222	1375	1528	1833	2139	3445	2750	3056	3361	3667	3973	4278	1/8
5/32	367	489	611	733	856	978	1100	1222	1467	1711	1956	2200	2445	2689	2934	3178	3423	5/32
3/16	306	407	509	611	713	815	917	1019	1222	1426	1630	1833	2037	2241	2445	2648	2852	3/16
1/4	229	306	382	458	535	611	688	764	917	1070	1222	1375	1528	1681	1833	1986	2139	1/4
5/16	183	244	306	367	428	489	550	611	733	856	978	1100	1222	1345	1467	1589	1711	5/16
3/8	153	204	255	306	357	407	458	509	611	713	815	917	1019	1120	1222	1324	1426	3/8
7/16	131	175	218	262	306	349	393	437	524	611	698	786	873	960	1048	1135	1222	7/16
1/2	115	153	191	229	267	306	344	382	458	535	611	688	764	840	917	993	1070	1/2
5/8	92	122	153	183	214	244	275	306	367	428	489	550	611	672	733	794	856	5/8
3/4	76	102	127	153	178	204	229	255	306	357	407	458	509	560	611	662	713	3/4
7/8	66	87	109	131	153	175	196	218	262	306	349	393	473	480	524	568	611	7/8
1	57	76	96	115	134	153	172	191	229	267	306	344	382	420	458	479	535	1
1 1/8	51	68	85	102	119	136	153	170	204	238	272	306	340	373	407	441	475	1 1/8
1 1/4	46	61	76	92	107	122	138	153	183	214	244	275	306	336	367	397	428	1 1/4
1 3/8	42	56	70	83	97	111	125	139	167	194	222	250	278	306	333	361	389	1 3/8
1 1/2	38	51	64	76	89	102	115	127	153	178	204	229	255	280	306	331	357	1 1/2
1 5/8	35	47	59	71	82	94	106	118	141	165	188	212	235	259	282	306	329	1 5/8
1 3/4	33	44	55	66	76	87	98	109	131	153	175	196	218	240	262	284	306	1 3/4
1/7/8	31	41	51	61	71	82	92	102	122	143	163	183	204	224	244	265	285	1/7/8
2	29	38	48	57	67	76	86	96	115	134	153	172	191	210	229	248	267	2
2 1/4	26	34	42	51	59	68	76	85	102	119	136	153	170	187	204	221	238	2 1/4
2 1/2	23	31	38	46	54	61	69	76	92	107	122	138	153	168	183	199	214	2 1/2
2 3/4	21	28	35	42	49	56	62	70	83	97	111	125	139	153	167	181	194	2 3/4
3	19	26	32	38	45	51	57	64	76	89	102	115	127	140	153	166	178	3
3 1/4	18	24	29	35	41	47	53	59	71	82	94	106	118	129	141	153	165	3 1/4
3 1/2	16	22	27	33	38	44	49	55	66	76	87	98	109	120	131	142	153	3 1/2
3 3/4	15	20	26	31	36	41	46	51	61	71	81	92	102	112	122	132	143	3 3/4
4	14	19	24	29	33	38	43	48	57	67	76	86	96	105	115	124	134	4
4 1/2	13	17	21	26	30	34	38	42	51	59	68	76	85	93	102	110	119	4 1/2
5	12	15	19	23	27	31	34	38	46	54	61	69	76	84	92	99	107	5
5 1/2	10	14	17	21	24	28	31	35	42	49	56	63	70	76	83	90	97	5 1/2
6	10	13	16	19	22	26	29	32	38	45	51	57	64	70	76	83	89	6
6 1/2	9	12	15	18	21	24	26	29	35	41	47	53	59	65	71	76	82	6 1/2
7	8	11	14	16	19	22	25	27	33	38	44	49	55	60	66	71	76	7
7 1/2	8	10	13	15	18	20	23	26	31	36	41	46	51	56	61	66	71	7 1/2
8	7	10	12	14	17	19	22	24	29	33	38	43	48	53	57	62	67	8
8 1/2	7	9	11	14	16	18	20	23	27	32	36	40	45	49	54	58	63	8 1/2
9	6	9	11	13	15	17	19	21	26	30	34	38	42	47	51	55	59	9
9 1/2	6	8	10	12	14	16	18	20	24	28	32	36	40	44	48	52	56	9 1/2
10	6	8	10	12	13	15	17	19	23	27	31	34	38	42	46	50	54	10
11	5	7	9	10	12	14	16	17	21	24	28	31	35	38	42	45	49	11
12	5	6	8	10	11	13	14	16	19	22	26	29	32	35	38	41	45	12
	15'	20'	25'	30'	35'	40'	45'	50'	60'	70'	80'	90'	100'	110'	120'	130'	140'