Computer Aided Manufacturing

Machining Calculation Notes

Outline
Cutting Speed
Feed Rate
Pocket Island Avoidance
Cusp Height Control
Sample Calculations

Cutting Speed - 1
The cutting speed v is the rate at which the tool edge
advances with respect to the part. This is given by the
formula v = 2 r /1000 , where v is in m/min, the tool radius
(for milling) or part radius (for turning) r is in mm, and is
the spindle speed in revolutions per minute (RPM).

Cutting Speed - 2
The cutting speed is chosen based on the tool / part material
combination. Generic values are listed in the Machinerys
Handbook1, and specific values are usually given by the
cutting tool supplier. Examples values are listed below:
Aluminum: HSS 200 m/min; Uncoated Carbide 600 m/min
4140 Steel: HSS 30 m/min; Uncoated Carbide 125 m/min

1Oberg,

E., Jones, F.D., Horton, H.L., and Ryffel, H.H., Machinerys Handbook,
24th Edition, Industrial Press, Inc., New York, NY, 1992.
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Feed Rate - 1
The feed rate is chosen to avoid tooth breakage, and
excessive tool deflection. Examples values are listed
below:
Aluminum: HSS End Mill, 6 mm axial depth of cut, 12 mm DIA tool 0.07
mm/tooth; 25 mm DIA tool, 0.13 mm/tooth;
Shell Face Mill, up to 0.50 mm/tooth
4140 Steel: HSS End Mill, 6 mm axial depth of cut, 12 mm DIA tool
0.03 mm/tooth; 25 mm DIA tool, 0.08 mm/tooth;
Shell Face Mill, up to 0.25 mm/tooth

The spindle speed (in RPM) is multiplied by the feed rate

per tooth and the number of teeth to obtain the feed rate per
unit time.

Pocket Island Avoidance - 1

Pockets are usually rough milled by lowering the tool to a
constant Z value, and then machining away material in the
XY plane. This strategy is often referred to as terrace
machining. Normally, for maximum Material Removal Rate
(MRR), large axial depth and radial width of cut values are
preferred. The axial depth is chosen to avoid machining
chatter. Although most modern CAD/CAM software supports
special corner clean-up tool paths, the radial width of cut is
usually chosen to avoid leaving corner islands that require
this special processing.
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Pocket Island Avoidance - 2

This requires that the step over or radial width of cut be
chosen between 50 percent and 100 percent of the tool
diameter. The maximum value permitted is computed using
the formula s = r * (1 + sin( / 2)) where s (mm) is the step
over, r (mm) is the tool radius, and is the corner angle.
The definitions are illustrated on the following slide.

Pocket Island Avoidance - 3

Cusp Height Control - 1

During finishing, the height of "cusps" that remain on the
final surface must be controlled. This restricts the maximum
feed per tooth along the path, and, for ball nose tools, the
maximum size of the step over between adjacent passes.
For a flat surface, the maximum value permitted is computed
2
2
using the formula s / 2 = r ( r h ) which, for h << r ,
simplifies to s = 8hr . The definitions are illustrated on the
next slide for a ball nose tool.

Cusp Height Control - 2

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Cusp Height Control - 3

For machining of filleted surfaces, the step over value is
stated as an angle subtended from the centre of the fillet.
Different formulae are used depending on whether the fillet
is internal (centre is in space) or external (centre is in part).
Calculation of the appropriate step over for these cases is
left as an exercise.

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Example Calculations - 1
1. A D = 20.0 mm diameter n = 2 flute HSS end mill is to be
used to clean out a 14 mm deep pocket (shape as
shown) in
aluminum. The
cutting speed is
to be v = 250
m/min, and the
feed s = 0.25
mm/flute.

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Example Calculations - 2
a. Calculate the pocket island avoidance step over
distance.
Solution:
The smallest corner angle is = 60 degrees. With a
cutter diameter of 20.0 mm, the step over distance is
s = r (1 + sin( / 2)) = 15.0 mm.
b. Calculate the feed mark cusp height at the specified
cutting conditions.
Solution:
2
From the formula h = s / 8r = 0.00078 mm.
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Example Calculations - 3
2. A D = 15.0 mm diameter n = 2 flute carbide ball nose
mill is to be used to finish a nearly flat tool steel surface.
The cutting speed is not to exceed v = 100 m/min and
the feed is not to exceed s = 0.3 mm/flute. The desired
cusp height is h = 0.001 mm. Calculate the step over,
spindle speed, and feed rate per minute.
Solution:
The step over is calculated from the formula s = 8hr
= 0.25 mm.
The spindle speed is calculated from the formula
= 1000v / D = 2122 rpm. The feed must be reduced
to 0.25 mm/flute to meet cusp height restrictions. With
this restriction, the feed rate is F = sn = 1062 mm/min.

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