Cutting Speed,

Feed, and Depth

of Cut
Session 13

Efficiency of a Milling
Operation
Cutting speed
Too slow, time wasted
Too fast, time lost in replacing/regrinding
cutters

Feed
Too slow, time wasted and cutter chatter
Too fast, cutter teeth can be broken

Depth of cut
Several shallow cuts wastes time
2

Cutting Speed
Speed, in surface feet per minute sfm or
meters per minute smm at which metal
may be machined efficiently
Work machined in a lathe, speed in
specific number of revolutions per min
(r/min) depending on its diameter to
achieve proper cutting speed
In milling machine, cutter revolves r/min
depending on diameter for cutting speed
3

Important Factors in
Determining Cutting
Speed

Type of workpiece material

Cutting tool material
Diameter of cutter
Surface finish required
Depth of cut taken
Rigidity of machine and work setup
4

Milling Machine Cutting

Speeds
High-Speed Steel Cutter

Material

ft/min

Alloy steel 4070

Carbide Cutter

m/min ft/min

m/min

1220

4575

Aluminum 5001000 150300

Bronze

65120

Cast iron

5080

Free m steel
Stnless steel
Tool steel

1525

60120

125200

3045 400600

2130 150250

3080

6070

10002000 30060

2035 200400

100150

Mach steel 70100

150250

1025
1820

4060

12018

4575
100300

125200

4060
5

Inch Calculations
For optimum use from cutter, proper
speed must be determined
Diameter of cutter affects this speed
Calculate speed required to revolve a 3-in. diameter
high-speed steel milling cutter for cutting machine
steel (90 sf/min).
simplify formula
CS(ft )
90
12xCS
4xCS
r / min

circumference(in.) 3x3.1416 3x 3.1416

D

4x 90 360
r / min

120
3
3

Metric Calculations
Formula for r/min of the milling machine
using metric measurement

simplify formula

CS( m )x1000 CSx1000 CS( m )x 320

r / min

x D(mm)
3.1416x D
D( mm)
Calculate the r/min required for a 75 mm diameter
high-speed steel milling cutter when cutting machine
steel (CS 30 m/min)

30 x320 9600
r / min

128
75
75
7

Cutting Speed Rules

for Best Results
1. For longer cutter life, use lower CS in
recommended range
2. Know hardness of material to be machined
3. When starting, use lower range of CS and
gradually increase to higher range
4. Reduce feed instead of increase cutter
speed for fine finish
5. Use of coolant will generally produce better
finish and lengthen life of cutter
8

Milling Machine Feed

Distance in inches (or mm) per minute that
work moves into cutter
Independent of spindle speed

Feed: rate work moves into revolving cutter

Measured in in/min or mm/min

Milling feed: determined by multiplying chip size

(chip per tooth) desired, number of teeth in
cutter, and r/min of cutter
Chip, or feed, per tooth (CPT or FPT): amount
of material that should be removed by each
tooth of the cutter
9

Factors in Feed Rate

1.
2.
3.
4.
5.
6.
7.

Depth and width of cut

Design or type of cutter
Sharpness of cutter
Workpiece material
Strength and uniformity of workpiece
Type of finish and accuracy required
Power and rigidity of machine, holding
device and tooling setup
10

Recommended Feed
Per Tooth - HSS
Sample Table Face Helical
See Table 60.2 in Text
Mills
Mills
Material

in.

mm

Alloy steel

.006

0.15 .005

Aluminum

.022

0.55

Slotting
and Side
Mills
in. mm in.
0.12 .004 0.1

.018 0.45 .013 0.33

Brass and bronze

(medium)Table shows
.014 feed
0.35
.011
.008
per tooth
for0.28
roughing
cuts0.2

Cast iron for finishing cut, the feed per tooth would be
or even 1/3
of0.25
value shown
(medium) reduced
.013to1/2
0.33
.010
.007 0.18
11

Recommended Feed
Per Tooth Cemented
Carbide
Sample Table
Slotting

See Table 60.3 in Face

Text
Mills
Material

in.

Aluminum

.020

Helical and Side

Mills
Mills
mm
0.5

in. mm in.
.016 0.40 .012 0.3

Brass and bronze

(medium)
.012 0.3
.010 0.25 .007 0.18
Cast iron Table shows feed per tooth for roughing cuts
cut, the feed
per
tooth.010
would 0.25
be
(medium) for finishing
.016 0.4
.013
0.33
reduced to1/2 or even 1/3 of value shown
12

Ideal Rate of Feed

Work advances into cutter, each
successive tooth advances into work
equal amount
Produces chips of equal thickness
Feed per tooth

F = no. of cutter teeth x feed/tooth x cutter r/min

Feed (in./min) = N x CPT x r/min

13

Feed Calculations
Inch Calculations
Find the feed in inches per minute using a
3.5 in. diameter, 12 tooth helical cutter to
cut machine steel (CS80)
First, calculate proper r/min for cutter:
r / min

4 x CS 4 x 80

91
D
3.5

Feed(in/min) = N x CPT x r/min

=12 x .010 x 91
= 10.9 or 11 in/min
14

Feed Calculations
Metric Calculations
Calculate the feed in millimeters per minute
for a 75-mm diameter, six-tooth helical carbide
milling cutter when machining cast-iron (CS 60)
First, calculate proper r/min for cutter:
r / min

CS x 320 60 x 320 19,200

256
D
755
75

Feed(in/min) = N x CPT x r/min

= 6 x .025 x 256
= 384 mm/min
15

Direction of Feed:
Conventional
Most
common
method
is to feed
work
against
rotation
direction of
cutter
16

Direction of Feed:
Climbing
When cutter
and workpiece
going in same
direction
Machine
equipped with
backlash
eliminator can
increase cutter
life up to 50%
17

Advantages of Climb
Milling
Increased tool life (up to 50%)
Chips pile up behind or to left of cutter

Less costly fixtures required

Forces workpiece down so simpler holding
devices required

Improved surface finishes

Chips less likely to be carried into workpiece
18

Advantages of Climb
Milling
Less edge breakout
Thickness of chip tends to get smaller as
nears edge of workpiece, less chance of
breaking

Easier chip removal

Chips fall behind cutter

Lower power requirements

Cutter with higher rake angle can be used
so approximately 20% less power required
19

Disadvantages of Climb
Milling
Method cannot be used unless machine
has backlash eliminator and table gibs
tightened
Cannot be used for machining castings
or hot-rolled steel
Hard outer scale will damage cutter

20

Depth of Cut
Roughing cuts should be deep
Feed heavy as the work and machine will
permit
May be taken with helical cutters having
fewer teeth

Finishing cuts should be light with finer

feed
Depth of cut at least .015 inch
Feed should be reduced rather than cutter
speeded up

21