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One of the most important factors affecting the efficiency of a milling operation is
cutter speed. If the cutter is run too slowly, valuable time will be wasted, while
excessive speed results in loss of time in replacing and regrinding cutters.
The cutting speed of a metal is defined as the speed in metres per minute at which the
metal can be machined efficiently. Its symbol is V. It is expressed in metre/min.
Formula:
or
V = d x π x n (m/min)
Example:
A cutter has a diameter of 10mm. What is the cutting speed when the spindle speed is
1000 rpm?
Solution : V=dxπ xn
1000
= 31.4 m/min
1. Selection of proper cutting speed
1.
Type of material to be machined. (Hard and tough materials require a lower cutting
speed than soft materials.)
2. Type of tool material. (High speed steel and carbide tool.)
3. Rigidity and condition of the machine.
4. Types of cutting operations. (Rough and finish.)
Since different types of materials vary in hardness, structure and machinability, different
cutting speeds must be used for each type of metal. The cutting speeds for the more
common metals are shown below.
Tool Steel 18 - 20 40 - 60
Cast Iron 15 - 25 40 - 60
Bronze 20 - 35 60 - 120
The spindle speed for milling is defined as the speed at which the spindle of a
milling machine rotates per minute.
Formula:
Cutting speed
Spindle speed =
dia. of cutter x π
or
n (rpm) = V
dxπ
Examples:
Calculate the speed required to revolve a 10 mm high-speed milling cutter when cutting
speed is 150 m/min.
Solution : n = V
dxπ
150 x 1000
= (convert to millimetre)
10 x 3.14
= 4777 rpm
3. Selection of Proper Spindle Speed
In order to obtain best results during machining, several factors need to be observed for
the selection of proper spindle speed.
1. For longer cutter life, use the lower cutting speeds in the recommended range.
2. Know the hardness of the material to be machined.
3. When starting a new job, use the lower range of the cutting speed and
gradually increase to the higher range if conditions permit.
4. If a fine finish is required, reduce the feed rather than increase the cutter
speed.
5. The use of coolant, properly applied, will generally produce a better finish and
lengthen the life of the cutter since it absorbs heat, acts as a lubricant and
washes chips away.
Feed
Feed in milling machine is defined as the distance in millimeters per minute that the work
moves into the cutter. It is expressed in mm/min.
Formula:
Feed = number of teeth in the cutter x recommended feed per tooth x rpm
or
f = N x feed/tooth x rpm
Example:
Calculate the feed in millimetres per minute for 10mm diameter and 6 tooth helical
milling cutter when machining a cast iron workpiece.
V
n =
dxπ
40 x 1000
= (convert to millimetre)
10 x π
= 1273 rpm
= 6 x 0.1 x 1273
= 763 mm/min
The feed rate used on milling depends upon several factors, such as:
The table below give suggested feed per tooth for various types of milling cutter
roughing cuts. For finish cuts, the feed per tooth should be reduced to half or even one-
third of the value shown.