Operating Conditions

Turning, Milling and Drilling

K. Govindarajan
Product Management & Technical Services

Operating Conditions
Depth of Cut
Feed Rate
Cutting Speed

Operating Conditions
Cutting speed
(m/min)

doc

Feed
(mm/rev)

Definition Of Speed (Cutting Speed Vc)

In turning, the peripheral speed of the work;
usually measured in meters/minute (m/min)
In Milling the peripheral speed of the Cutter;
usually measured in meters/minute (m/min)
In Drilling the peripheral speed of the Drill;
usually measured in meters/minute (m/min)
4

Cutting Speed(Vc) vs. RPM

Vc- dependant on diameter of work piece / Cutter / Drill
RPM - not dependant on diameter.
(305 mm)
(100 mm)

Vc(m/min)= 3.14 x Workpiece Dia x RPM

1000
5

Cutting Speed (Vc) vs. RPM

Vc= 3.14 x Cutter Diameter x rpm
1000

Vc - dependant on
diameter

Effective Diameter

Definition Of Feed mm/rev

TURNING: The relative amount of motion of the tool into the
work for each spindle revolution. Usually measured in
mm/revolution (mm/rev)
MILLING: The movement of the Cutter into the workpiece.
Usually measured in millimeter per minute (mm/min)]
[millimeter per Tooth (mm/tooth)]
DRILLING: The Axial motion of the tool into the work for
each revolution, stroke, or unit of time. Usually measured in
mm per revolution (mm/rev )

Definition Of Depth of Cut (doc)

For Turning The distance between the bottom of the cut and
the uncut surface of the work, measured in a direction at right
angles to the machined surface of the work.*

For Drilling
Depth of Cut = the
diameter of the drill

Depth Of Cut - Milling

Radial DOC

Axial DOC

In Milling Depth of Cut is normally associated

with Axial Depth of Cut.
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TURNING CONDITIONS
Workpiece Material 4140 Alloy Steel
Hardness 250 HB
Continuous Cut
Stock Remaining For Finish Pass -0.5 mm / side
Workpiece Diameter = 97 mm
Length of Cut =216 mm
Finish required = 1.2 Ra (mm)
Rigid Setup

10

Determine Machine RPM:

Cutting speed is defined as the distance in mtrs
that is travelled by a point on the work piece periphery
in one minute.
Vc= RPM x Cutter Circumference
Circumference = Pi x Diameter, Where
Pi = 3.14..
RPM =

Vc
Cutter Circumference

RPM =

Vc

Vc = RPM x 3.14D
RPM =

Vc
.
Circumference

= Vc

3.14D

Pi x Diameter
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Vc
3.14D

RPM=

Because we work in (mm) more than we do in (mtr),

we need to convert the (mtr)in Vc to (mm).
Since there are 1000mm in 1 mtr.
RPM =

Vc x (1000mm)
3.14D (1 m)
Hence,
RPM = 1000 Vc
3.14 x D (mm)
12

Determine Machine RPM:

GIVEN: Workpiece Diameter = 97 mm
Cutting Speed (Vc) = 300 m/min
-------------------------------------------------------------------RPM =

Vc x 1000
3.14 x Dia(mm)
300 x 1000
3.142 x 97

=984 RPM

13

Determine Metal Removal Rate (MRR)

TURNING (cm3/min)
GIVEN: Cutting Speed = 300 m/min
Depth of Cut = 0.5mm or 0.05 cm
Feed Rate = 0.4mm/rev
-----------------------------------------------------------------------MRR = Vc X DOC X FEED RATE
= Vc m x DOC mm x fr mm
min
rev
= 300 m x 0.05cm x 0.04cm x100cm

min

rev

=60cm3/min

14

Determine Cutting Time (min.):

GIVEN: Machine RPM = 984 RPM
Length of Cut = 216 mm
Feed Rate
= 0.4 mm/ rev
-----------------------------------------------------------------------Cut Time = Length Of Cut
= 216 mm
Feed Rate x RPM
0.4 mm x 990 rev
rev
min
= 216 min
0.4 x 984
= 0.549 min
= 32.94 seconds
15

Determine Machine Vc:

Lets say we made a mistake, our workpiece is 9.7mm
not 97mm, If the maximum RPM on our lathe is 5,000 RPM
We proved that RPM = Vc x 1000
3.14 x Dia
Vc = 3.14 x Dia x RPM
1000
= 3.142 X 9.7 X 5000
1000
= 152m/min

16

Turning Formulas (metric)

To Find

Formula

Vc

3.14 D N
1000
Vc x 1000
3.14 D
mm/min
RPM
mm/rev x RPM

RPM
f r (mm/rev)
fmm/min
Cut time

Length of cut
mm/rev x rpm

17

Feed Rate- Milling

F = fz x Z x RPM
(mm/min)

fz

(mm/tooth)

F (mm/min)
Z x RPM

f =
(mm/rev)

F .
RPM

Feed rate in mm per minute (mm/min)

is measured as the total advance of the
cutter per minute.(w.r.t to table)
Feed Rate (mm) per tooth
(mm/tooth) is measured by the
amount of metal cut by each tooth on
each revolution of the cutter (fz).

18

MILLING CONDITIONS
Workpiece Material Gray Cast Iron Class 20
Hardness 250 BHN
Radial Width of Cut = 100 mm
Axial Depth of Cut = 2.5 mm
Diameter of Cutter = 160 mm
Number of Inserts In Cutter = 10
0 Lead Angle Cutter
50HP Machine / Rigid Setup

19

STARTING PARAMETERS
From Table
Kyon 3500
Starting Cutting Speed 700 mtrs/min
Feed 0.15 mm/tooth
Dry

20

Determine Machine RPM:

GIVEN: Cutter Diameter = 160 mm
Cutting Speed = (700 mtrs/min)
RPM = Cutting Speed x 1000 =
Diameter x 3.14

700 x 1000
160 x 3.14

=1393 rev/min

21

Determine Feed Rate (mm/min):

Milling
GIVEN: Number of Inserts In Cutter = 10
Machine RPM = 1393
Chip Load = 0.15 mm/tooth

F = fz x No. of Teeth x RPM

= 0.15 X 10 X 1393
= 2090 mm/min
22

Determine Metal Removal Rate

(cm3/min):
GIVEN: Axial Depth of Cut = 2.5 mm
Feed Rate = 2090 mm/min
Radial Width of Cut = 100 mm
MRR = RWOC x ADOC x Feed Rate
= 100 x 2.5 x 2090
1000
= 522.5 cm3/min

23

Formulas
To Find

Given

Formula

Vc

D, rpm

Vc = 3.14 x D x RPM
1000

RPM

D, Vc

RPM = Vc x 1000

3.14 x D
f

f =

F / RPM

fz, Z, RPM F =

fz x Z x RPM

fz

F, Z, RPM

fz =

F .
Z x RPM

fz

Z, f

Fz =

F / Z

Legend
Vc

Cutting Speed

Feed per revolution

Feed per minute

fz

Feed per tooth

No. of effective tooth or inserts in cutter

3.14

3.1416
24

DRILLING CONDITIONS
Workpiece Material 303 Austenitic Stainless Steel
Hardness 200 BHN
Diameter of Drill = 32mm
Depth of Hole = 76mm
Horizontal Application
High Pressure Coolant Available
Hole Tolerance Required 0.1

25

STARTING PARAMETERS
KSEM DRILL
From Table
Starting Speed 70m/min
Feed 0.3mm/rev

26

Determine Machine RPM:

GIVEN: Diameter of Drill =32 mm
Cutting Speed = 70 M/Min.
-----------------------------------------------------------RPM = (Cutting speed x 1000) / (3.1415 x Diameter (mm) )
RPM = ( 70 X 1000) / ( 3.1415 X 32) = 696

27

Determine Feed Rate (mm / min.)

GIVEN: Feed Rate = 0.3mm / rev.
Machine RPM = 696 RPM
--------------------------------------------------------Feed rate ( MM/Min) = RPM X Feed (mm/rev)
Feed rate ( MM/Min.)= 696 x 0.3
RESULT: 209 mm / min.

28

Determine Metal Removal Rate

(cm / min.):
GIVEN: Diameter 32mm (D )
Feed mm/min. = 209mm / min.
-----------------------------------------------------------------------MRR = Pi (D) x Feed mm/min.
4
1000
= (3.14) (32mm.) x 209mm/min.
4
1000
= 168 cm / min.
29

BASIC FORMULAS
To find
Cutting Speed
Vc
rpm

Formula
3.14 x d x rpm
1000
(m/min)
1000 x Vc
3.14 x d

mm per rev

mm per min
rpm

mm per min

mm per rev x rpm

Cut time
MRR

Drill hole depth

mm per min ( min)
d2
4

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