machinist group of northeast indiana cutting tool theory intro speeds and feeds july 8, 2014
TRANSCRIPT
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Machinist Group of Northeast Indiana
Cutting Tool Theory IntroSpeeds and Feeds
July 8, 2014
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What RPMs & IPM would you run?• Specifications (dry machining)• Material: 1018 CRS• Endmill:
– 5/8” diameter (.625)– 8 flute– High Speed Steel– TiN Coating
• Amount to remove– “Z” total depth = 1.22”– “Y” total material = 3.5”– “X” total material = 6.25”
Machine limits7.5 horsepower
550-10,000 RPMs200 IPM max (X&Y axis)
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Important Formulas(applies to any rotating tool)
OR better known as
n =Vc x 12p x Dm
RPM = SFPM x 3.82Diameter
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Lathe (Sandvik Coromant)Dm Machined diameter mm (inch) mm (inch) fn Feed per revolution mm/r (inch/r) ap Cutting depth mm (inch) n Spindle speed rpm Pc Net power kW (HP)
Q Metal removal rate cm3/min (inch3/min)
hm Average chip thickness mm (inch)
hex Maximum chip thickness mm (inch)
Tc Period of engagement min lm Machined length mm (inch) kc Specific cutting force N/mm2 (N/inch2) KAPR Entering angle degree PSIR Lead angle degree
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Milling Machines(multi-flute cutters)
Vf = n x Fz x ZnOR
IPM = RPM x IPT x # of Flutes
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Milling(Sandvik Coromant)
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Milling: Up or Down?• Conventional Milling (fights the rotation)
– Aka: UP milling– Starts at ZERO chip thickness and progresses to MAX– In most materials, should only be used with machines
with backlash• Climb Milling (acts like a wheel)
– Aka: Down Milling– Starts at MAX chip thickness and progresses to ZERO– In most materials and set-ups, this is the best choice
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Face Milling
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Climb MillingFeed per Tooth
Maximum chipthickness
average chip thickness
Workingengagement
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Traditional Milling Engagement
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Radial Chip Thickness
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How does new concepts in metal cutting help us on smaller machines?
• Specifications (dry machining)– Material: 1018 CRS– Endmill:
• 5/8” diameter (.625)• 8 flute• High Speed Steel• TiN Coating
– Amount to remove• “Z” total depth = 1.22”• “Y” total material = 3.5”• “X” total material = 6.25”
Machine limits7.5 horsepower
550-10,000 RPMs200 IPM max (X&Y axis)
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What we ran at SA with our old tools
• RPM = 2200• IPM = 190 • 1.22 = “Z” depth of cut per pass
– Total depth needed to finish part• .030 = “X” step over (radial width of cut)
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Results:• It took 208 passes to finish the part• 3 minutes 50 seconds: Total time to remove 27
in3 of steel• We actually changed our cutting to G00 (rapid)
moves• Cutter looked like it was new when we were
done• Part and tool was cool enough to touch at the
completion of the material removal
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Good Reading:
• Cutting Tool Engineering Magazine• “Limited Engagement” by Bill Kennedy• July 2011 / Volume 63 / Issue 7• http://www.ctemag.com/aa_pages/2011/110
705-Milling.html