MILLING SPEED & FEED CALCULATOR - INCH to METRIC

3.940 CUTTER DIAMETER INCHES CUTTER DIAMETER MILLIMETERS 500 CUTTING SPEED FEET PER MINUTE CUTTING SPEED METERS / MINUTE

100.1

152.4

(Z) EFFECTIVE FLUTES

0.0100

FEED RATE INCHES / TOOTH FEED RATE / TOOTH MM

0.254

600

SFM

EQUALS

182.88

METERS MINUTE

58.00

INCHES / EQUALS MINUTE

MILLING SPEED & FEED CALCULATOR - METRIC to INCH

100 CUTTER DIAMETER MILLIMETERS CUTTER DIAMETER INCHES 150 CUTTING SPEED METERS / MINUTE CUTTING SPEED FEET PER MINUTE

3.94

492

(Z) EFFECTIVE FLUTES

0.254

FEED RATE / TOOTH

MM

0.0100

FEED RATE INCHES / TOOTH

600

METERS/ EQUALS MINUTE

1968

SFM

58.00

MM/ MINUTE

EQUALS

TURNING SPEED & FEED CALCULATOR - INCH TO METRI

1.0000 PART DIAMETER INCHES PART DIAMETER MILLIMETERS FEED RATE INCH/REV (IPR) DEPTH OF CUT INCHES (DOC) 200 CUTTING SPEED FEET PER MINUTE CUTTING SPEED METERS/MINUTE FEED RATE MM/REV (MMPR) DEPTH OF CUT/MM (DOC)

25.40

60.96

0.005

0.127

0.03

0.762

300

SFM

EQUALS

91.44

METERS MINUTE

70.00

INCHES / EQUALS MINUTE

TURNING SPEED & FEED CALCULATOR - METRIC TO INC

101.60 PART DIAMETER MILLIMETERS PART DIAMETER INCHES FEED RATE MM/REV (MMPR) DEPTH OF CUT/MM (DOC) 100 CUTTING SPEED METERS/MINUTE CUTTING SPEED FEET PER MINUTE FEED RATE INCHES/REV (IPR) DEPTH OF CUT INCHES (DOC)

4.0000

328.1

0.10

0.0039

0.03

0.0012

600

METERS/ EQUALS MINUTE

1968

SFM

58.00

MM/ MINUTE

EQUALS

- INCH to METRIC

485

RPM

24.24

TABLE FEED INCHES / MIN. TABLE FEED / MIN. MM

615.7

1473.2

MM / MINUTE

- METRIC to INCH

477

RPM

606.4

TABLE FEED / MIN.

MM

23.87

TABLE FEED INCHES / MIN.

2.283

INCHES/ MINUTE

- INCH TO METRIC

764

RPM

1778.00

MM / MINUTE

- METRIC TO INCH

313

RPM

2.283

INCHES/ MINUTE

CIRCLE INTERPOLATION MILLING CALCULATOR

NOTE: During internal circle interpolations, the outside diameter of a milling cutter advances faster than the centerlin tool. This will produce a thicker chip than the calculated feed rate. (IPT) During external circle interpolations, the outs diameter of a milling cutter will advance slower than the centerline of the tool. This will produce a thinner chip than th calculated feed rate. (IPT) When less than 1/2 of the diameter of the tool is engaged (radial) with the workpiece, there be radial chip thinning effects. This calculator solves for both effects. Enter the cutter diameter, radial width of cut (W internal or external circle diameter (diameter being produced, not starting diameter) and the desired chip load per too The calculator will give you the "adjusted" feed rate (IPT) to maintain the desired chip thickness.

INTERNAL APPLICATIONS

0.125

Cutter Diameter

0.750

Circle Diameter (after

the cut)

0.010

Radial Width of Cut (WOC)

0.0050

Desired Chip Load (IPT)

0.0077

Adjusted Chip Load (IPT)

NOTE: If the operation is not a full circle interpolation, simply input into the "Circle Diameter" data cell what the theoretical circle size would be

EXAMPLE: A 1.00 inch diameter end mill cuts an internal 90 degree corner that has a .625 inch radius. The circle diameter is the radius X 2, or 1.2 For ID operations the radius of the cutting tool must always be equal to or smaller than the radius to be interpolated. Whenever practical , try to h tool diameter be less than or equal to about 1/3 of the diameter to be interpolated

EXTERNAL APPLICATIONS

1.000

Cutter Diameter

4.000

Circle Diameter (after

the cut)

0.500

Radial Width of Cut (WOC)

0.0050

Desired Chip Load (IPT)

0.0063

Adjusted Chip Load (IPT)

NOTE: If the operation is not a full circle interpolation, simply input into the "Circle Diameter" data cell what the theoretical circle size would be
EXAMPLE: A 1.00 inch diameter end mill cuts a 45 degree corner that has a 4.00 inch radius. The circle diameter is the radius X 2, or 8.00 inches. practical , it is a good idea to have the tool diameter greater than about 1/2 of the radial width of cut on external interpolations.

G CALCULATOR

advances faster than the centerline of the ernal circle interpolations, the outside will produce a thinner chip than the (radial) with the workpiece, there will also ter diameter, radial width of cut (WOC), the and the desired chip load per tooth. (IPT) ip thickness.

l what the theoretical circle size would be. he circle diameter is the radius X 2, or 1.250 inches. interpolated. Whenever practical , try to have the

l what the theoretical circle size would be. diameter is the radius X 2, or 8.00 inches. Whenever xternal interpolations.

Radial Chip Thinning Calculator

NOTE: For use when less than 1/2 of the diameter of milling cutter is engaged in the width of cut (WOC) and for all slo type cutters. The chip thickness produced with less than 1/2 of the diameter in radial contact will be thinner than calc feed per tooth due to radial chip thinning. Enter the "desired chip load" (IPT) into the calculator. The calculator will g "adjusted" feed rate (IPT) to produce the desired chip thickness. 0.5000 TOOL DIAMETER 0.5000 RADIAL WIDTH OF CUT (WOC)

0.0045

DESIRED CHIP LOAD (IPT)

0.0045

ADJUSTED CHIP LOAD (IPT)

0.0045

Actual maximum chip thickness if Radial Chip Thinning Calculation is not used.

1.0000

The output from these calculations are correct for linear machining (straight line) applications. During circle interpolations and other milling ap where a radius is generated, other factors must be accounted for. Refer to the Circle Interpolation Calculator.

lculator

width of cut (WOC) and for all slotting l contact will be thinner than calculated e calculator. The calculator will give the

RADIAL WIDTH OF CUT (WOC)

ADJUSTED CHIP LOAD (IPT)

Radial Chip Thinning Factor

circle interpolations and other milling applications ircle Interpolation Calculator.

Milling Lead Angle Chip Thinning Calculator

Lead approach angles on milling cutters produce a thinner chip than the actual advance per tooth. Enter the desired c into the calculator. It will provide the adjusted feed per tooth to obtain the desired chip thickness. The chip thinning equal to the cosine of the approach angle.

0.005

Desired Chip Load (IPT)

45

Approach Angle

0.0071

NOTE: Enter the approach angle from "0" degrees. As an example, a tool that cuts a 90 degree square shoulder has a "0" degree lead.

Common Iscar Tools

F90 & E90 E75 & F75 E45 & F45 E30 E60 0 Degree 15 Degree 45 Degree 60 Degree 30 Degree

0.0035

Actual Chip Thickness if Adjustment is not made

ing Calculator

ance per tooth. Enter the desired chip load hip thickness. The chip thinning factor is

Adjusted Chip Load (IPT)

shoulder has a "0" degree lead.

THEORETICAL MILLING SIDE WALL FINISHES

3.000
TOOL DIAMETER

NUMBER OF FLUTES

0.0060

FEED RATE (IPT)

75

THEORETICAL SURFACE FINISH (in)

This calculation is for reference purposes only. It applies to indexable insert milling cutters. The values for solid carbide tools will be significantly lower based on tool run out, helix angle and other factors.

a.p.r . 250000 = R t (in) D

wall finish. Use this calculator to estimate the resultant finishes at high feed rates.

Rt

NOTE: When using the Radial Chip Thinning Calculator, extremely high feed rates can result. These feed rates may produce an unacceptable side

CALCULATIONS PAGE
COMMON CONVERSIONS & CALCULATIONS
ENTER IN WHITE RESULTS IN YELLOW ENTER IN WHITE Down
RESULTS IN YELLOW

SFM 450 Cutter Diameter: RPM 950 Cutter Diameter: IPM 60 # Effective Flutes: IPT 0.0045 # Effective Flutes: IPT 0.006 # Effective Flutes: IPR 0.0360 # Effective Flutes: HORSEPOWER 1 KILOWATTS 8.110 FEET 1 METERS 200 INCHES 1 METERS 1 BRINELL HARDNESS 440 ROCKWELL C 32 FAHRENHEIT 0.0 CELSIUS 0.0

TO 0.500 TO 3.000 TO 4 TO 1 TO 6 TO 6 TO

RPM 3438.0

THREAD HELIX ANGLE Threads Per Inch Thread Diameter 60 0.5 HELIX ANGLE: 0.61
NUMBER OF THREADING PASSES - 60 DEGREE FORMS

SFM 746.1

Threads per Inch

UN Thread Depth External:

12 0.0526

8
UN Internal:

Passes 0.0451

IPT 0.0214 RPM: 700 IPM 15.750 RPM: 3500 IPR 0.036

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NUMBER OF THREADING PASSES - ACME FORMS Threads per Inch 6 13 Passes Acme thread depth External 0.0950 Acme Internal 0.0980
NUMBER OF THREADING PASSES - STUB ACME FORMS

Threads per Inch

Stub thread depth External

16 0.0240

5
Stub Internal

Passes 0.0248

NUMBER OF THEADING PASSES - NPT FORM Threads per Inch 8 15 Passes 0.1000 NPT Thread Depths, External & Internal DIMINISHING INFEED PER PASS - THREADING Total Thread Depth 0.095 # Passes 13 Depth of Cut per Pass Pass 1 - 4 0.0150 0.0124 0.0114 0.0087 #5 - 8 0.0073 0.0065 0.0059 0.0054 #9 - 12 0.0050 0.0047 0.0045 0.0042 #13 - 16 0.0040 0.0000 0.0000 0.0000 #17 - 20 0.0000 0.0000 0.0000 0.0000 TURNING SURFACE FINISHES Corner Radius 0.03200 IPR Resulting Surface Finish (Ra) Desired Surface Finish (Ra) Corner Radius 0.01600 IPR

IPT 0.006

KILOWATTS 0.746 HORSEPOWER 10.876 METERS 0.3048 FEET 656.1680 METERS 0.0254 INCHES 39.3701 ROCKWELL C 47 BRINELL HARDNESS 302 CELSIUS -17.8 FAHRENHEIT 32.0
Up Down

TO

TO

0.0100 124 16 0.0025

TO

TO

TO

Desired Surface Finish (Ra) 32 Corner Radius 0.03101 IPR 0.0050 All Surface Finish calculations are based on 80 degree diamond or trigon inserts. 55 & 35 degree inserts will have rougher Ra values.
**FOR TURNING & DRILLING NON-INTERUPTED CUTS** THEORETICAL TOOL LIFE @ 15 MINUTES CUTTING TIME TIME IN CUT (MIN/PART) # PARTS 0.055 273

TO

TO

TO

ACTUAL TIME IN CUT PER INSERT - MILLING TOOL DIAMETER: AVE. WOC: 1 0.5 TIME IN CUT (MIN/PART) MIN/INSERT 0.2500 1 TOOL LIFE / CUTTING SPEED ADJUSTMENTS SFM WILL ACHIEVE: 958 5 MIN/LIFE SFM WILL ACHIEVE: 916 10 MIN/LIFE SFM WILL ACHIEVE: 833 15 MIN/LIFE SFM WILL ACHIEVE: 791 20 MIN/LIFE SFM WILL ACHIEVE: 750 25 MIN/LIFE SFM WILL ACHIEVE: 725 30 MIN/LIFE SFM WILL ACHIEVE: 666 45 MIN/LIFE SFM WILL ACHIEVE: 625 60 MIN/LIFE
To Top (Enter a cutting speed that attains 15 minutes of tool life)

TO

Turning Surface Finishes

Enter Information In White Data Cells
Data Returned Gives Theoretical Ra Values in Micro Inches - To conver to RMS Multiply by 1.1 - (Ra X 1.1) Calculations Are Based On 80 Degree Insert Geometry - 55 & 35 Degree Inserts Will Give Higher Values

To Find Resulting Ra
Insert Corner Radius Tool Feed Rate Inches 0.0060 Per Revolution

0.0150

Resulting Ra

95

To Find Required Feed Rate (IPR)

Ra Finish Requirement

60

Insert Corner Radius

0.0150

Feed Rate Required (IPR)

0.0049

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BALL NOSE & ROUND INSERT CUTTING CALCULATIONS & ADJUSTMENTS

SPEED AND FEED CALCULATIONS

ENTER REQUIRED INFORMATION IN WHITE

DESIRED CUTTING SPEED (SFM) DESIRED FEED RATE (IPT) NUMBER OF EFFECTIVE FLUTES

300 0.003 Inches 2

INSERT OR ENDMILL DIAMETER DEPTH OF CUT - (DOC) RADIAL CHIP THINNING FACTOR

1 0.03 0.3412

Inches

Inches

TRUE TOOL DIAMETER

CORRECTED RPM

ADJUSTED FEED RATE (IPT)

CORRECT TABLE FEED (IPM)

0.3412

3,359

0.0088

59.07

ROUND INSERT & BALL NOSE CUTTER SURFACE FINISHES

ENTER REQUIRED INFORMATION IN WHITE ****SURFACE FINISHES ARE THEORETICAL AND GIVEN IN Ra VALUES - RMS = Ra x 1.11**** RESULTING SURFACE FINISH IN Ra REQUIRED STEPOVER TO ACHIEVE Ra DIAMETER TO ACHIEVE Ra

TO FIND:

20.3
ENTER
TOOL DIAMETER: TOOL STEP OVER: SURFACE FINISH - Ra:

0.0050
0.5000

0.18

0.2500 0.0080

0.0030 4.0
****TO FIND Rt****

4.0

INSERT OR TOOL DIAMETER

0.5

TOOL STEP OVER

0.03

Rt:

0.0004504057

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