Tools with ISO elements | Technical appendix | Calculation of cutting forces, boring

Calculation of cutting forces, boring

(simplified)

ø 72 pre-drilled
ø 80

Example calculation: Boring tool ø 80 mm; Material: EN-GJL-250

Z = 5; pre-drilled ø 72 mm κ = 90° kc1.1* = 1160 mc = 0.26
vc 200 m/min fz= 0.2 mm
Blunting 30 %

Basic formula Calculation Result

Vc · 1000 200 · 1000

1. Spindle speed n = –––––––– n = –––––––– n = 800 1/min
�·D � · 80

(D – d) (80 – 72)
2. Cutting depth ap = –––––––– ap = –––––––– ap = 4 mm
2 2

3. Cutting cross section A = ap · f · z A = 4 mm · 0,2 mm · 5 A = 4 mm2

4. Chipping thickness h = fz · sin κ h = 0,2 mm · sin90º h = 0,2 mm

kc1.1 1160
5. Specific cutting kc = –––––––– kc = –––––––– kc = 1763 N/mm2
force h mc 0,2 0,26
without blunting with 30 % blunting:
factor
1763 N/mm2 × 1,3 =
2292 N/mm2

6. Cutting force Fc = A · kc = b · h · kc Fc = 4 mm2 · 2292 N/mm2 Fc = 9,17 kN

7. Cutting torque dm 0,076 m

dm = average Mc = Fc ––––– Mc = 9167,3 N ––––––– Mc = 348,3 Nm
diameter in metres 2 2

2 · � · n · Mc 2 · � · 800 min-1 · 348,3 Nm

8. Cutting power Pc = ––––––––––– Pc = ––––––––––––––––––––––– Pc = 29,2 kW
60s 60s
* Value for cutting force calculation, WTO GmbH Note: The efficiency of the main spindle drive is not taken into account.
Appropriate power calculations can be made by MAPAL.
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 Tools with ISO elements | Technical appendix | Calculation of cutting forces, boring

Machine tool selection:

Comparison with torque and output power of the machine tool Motor spindle (Figure 1)
Torque (Nm) Power (kW)
There follow two spindle speed/power diagrams.
The number of teeth and cutting parameters are to be defined as a 35 kW 100%
function of the machine. 40
630
400 30
In the example calculation the machine with the motor spindle is
200 187 Nm 100% 20
unsuitable, as here at a spindle speed of 800 1/min a torque of
10
187 Nm and a power of approx. 20 kW is achieved (Figure 1).
160 8

100 5
3,15
40 2

10

5 1000 0,6

1600

4000

10.000
Torque curve in Nm Spindle speed (1/min)
Power curve in kW
Line to assist on reading the diagram

Solution: Geared spindle (Figure 2)

Either reduce number of teeth, reduce cutting speed and feed,
Torque (Nm) Power (kW)
divide cut between two tools or select more powerful machine
(e.g. with geared spindle, (Figure 2). 42 kW 100%
40
630 400 Nm 100%
400 30
200 20
10
160 8

100 5
3,15
40 2

10

5 0,6
1000

1600

4000

10.000

The example diagrams are shown in a simplified form. Spindle speed (1/min)
Technical
appendix

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