Milling Cycle-Time Calculation

Milling
Ref.N
Part No Part Description Raw material RM Size
o
1 76009914-001 Cover, Tranformer Al Alloy 6061-T6 100 x 100 x 6.35
Heatsink, TADS/PNVS power supply

2 76009924 Al Alloy 6061-T651 175 X 160 X 38
(TPPS)
Cover, tactical, programmable power

3 76009928-001 Al Alloy 6061-T651 165 x 146 x 31.75
supply (TPPS)
Page 1
Milling
Cover, tactical, programmable power
3 76009928-001 Al Alloy 6061-T651 165 x 146 x 31.75
supply (TPPS)
4 76009953 Plate, Access, PSI Al Alloy 6061-T6 100 x 90 x 6.35
5 76009952-001 Cover, RPS Al Alloy 6061-T651 220 x 160 x 50.8
7 76009954 Bracket Assy, Connector Mounting

Page 2 Al Alloy 6061-T651 95 x 31.75 x 6.35
Milling
7 76009954 Bracket Assy, Connector Mounting Al Alloy 6061-T651 95 x 31.75 x 6.35
11.1.1 - Top panel Al Alloy 6061-T651 280 x 230 x 31.75
290 x 31.75 x
11.2 - Front Panel Al Alloy 6061-T651
19.05
11.3.1
& - Left Panel & Right Panel Al Alloy 6061-T651 280 x 190 x 30
11.4.1
11.5.1 - AFT Panel Al Alloy 6061-T651 300 x 190 x 44.5

Page 3
Milling
11.5.1 - AFT Panel Al Alloy 6061-T651 300 x 190 x 44.5
15-5PH
12 76009906 Bracket, Mounting CSUE 55 x 38.1 x 22.225
CONDITION 'A'
13 76009951 Cover Front PSI Al Alloy 6061-T651 240 x 177.8 x 12.7
14 76009948 Bracket, Cable Mount Al Alloy 6061-T651 105 x 72 x 5.08
Page 4
14 76009948 Bracket, Cable Mount Al Alloy 6061-T651 105 x 72 x 5.08
Milling
15 76009944 Cover, Access, Rear, VPC Al Alloy 6061-T651 95 x 25.4 x 6.35
16 76009918 Cover, Access, Rear, VPC Al Alloy 6061-T651 235 x 190 x 3
Chassis, Brazement, Power AID

21 76009943 Al Alloy 6061-T651 260 x 190 x 63.5
system interface (PSI)
Page 5
Milling
Length of
Type of Operation Cutter Diameter (mm) No of cutting teeth
component
Milling 12 3 100
Milling 10 3 78.74
Milling 3 3 370.8
Milling
Milling 16 3 175
Milling 12 3 139
Milling 5 3 592
Milling 8 3 157.988
Milling 3 3 8.255
Milling 5 3 300
Milling 5 3 170.18
Milling 6 3 623.4176
Milling 5 3 97.7392
Milling 5 3 22.86
Milling
Milling 16 3 165
Milling 16 3 131
Milling 16 3 138
Milling 3 3 520
Page 6
Milling
Milling 1.5 3 130
Milling 8 3 591
Milling
Milling 12 3 100
Milling 6 3 329.946
Milling
Milling 20 3 220
Milling 8 3 707.39
Milling 12 3 160.5788
Milling 12 3 555.498
Milling 16 3 206.375
Milling 16 3 184.15
Milling 4 3 84.582
Milling
Milling
Milling
Milling
Milling
Milling
Milling
Milling 8 3 85.217
Page 7
Milling
Milling 3 3 43.18
Milling 20 3 280
Milling 16 3 193.04
Milling 3.175 3 193.04
Milling 16 3 215.9
Milling 10 3 1020
Milling 4 3 15.494
Milling 12 3 275
Milling 4 3 50
Milling
Milling 20 3 280
Milling 6 3 46.99
Milling 6 3 34.1376
Milling 20 3 212.09
Milling
Milling
Milling
Milling 20 3 300
Milling 16 3 259.08
Milling 16 3 111.506
Milling 16 3 268.8336
Page 8
Milling
Milling 6 3 180.594
Milling 6 3 119.38
Milling 6 3 91.4908
Milling 12 3 33.655
Milling 3 3 33.655
Milling 4 3 33.655
Milling 12 3 33.2232
Milling 6 3 59.8551
Milling
Milling
Milling 16 3 240
Milling 12 3 206.883
Milling 12 3 739.648
Milling 12 3 85.79231
Milling 12 3 81.003902
Milling 12 3 95.76816
Milling 12 3 123.301506
Milling 12 3 133.277356
Milling
Milling 8 3 74.168
Milling 5 3 33.119822
Milling 6 3 400
Page 9
Milling
Milling 10 3 95
Milling 5 3 11.176
Milling 2.5 3 33.655
Milling 6 3 801.116
Milling 20 3 260
Milling 20 3 838.2
Milling 8 3 838.2
Milling 10 3 215
Milling 6 3 22
Milling 10 3 213
Milling
Page 10
Milling
Machining parameters
Table feed
Depth of cut
mm/min
Cutting Speed Feed mm/min (Chart
Spindle Speed (rpm)
m/min (Chart Value) Value)
25.00 0.20 663.06 397.84 1.50
20.00 0.18 636.54 343.73 0.50
15.00 0.15 1591.34 716.10 1.00
100.00 0.05 #DIV/0! #DIV/0! 0.20
35.00 0.35 696.21 731.02 1.50
35.00 0.25 928.28 696.21 1.00
20.00 0.15 1273.07 572.88 1.00
35.00 0.25 1392.43 1044.32 1.00
18.00 0.08 1909.61 458.31 0.30
20.00 0.08 1273.07 305.54 0.20
20.00 0.08 1273.07 305.54 0.20
35.00 0.10 1856.57 556.97 0.20
18.00 0.10 1145.77 343.73 0.20
20.00 0.08 1273.07 305.54 0.20
20.00 0.08 #DIV/0! #DIV/0! 0.20
40.00 0.35 795.67 835.46 1.50
35.00 0.30 696.21 626.59 0.50
35.00 0.30 696.21 626.59 1.00
20.00 0.12 2121.79 763.84 1.00
Page 11
Milling
20.00 0.05 4243.58 636.54 1.00
40.00 0.25 1591.34 1193.51 1.00
20.00 0.12 #DIV/0! #DIV/0! 1.00
25.00 0.20 663.06 397.84 1.50
25.00 0.20 1326.12 795.67 0.50
100.00 0.05 #DIV/0! #DIV/0! 0.20
45.00 0.40 716.10 859.33 1.50
40.00 0.15 1591.34 716.10 0.50
40.00 0.30 1060.90 954.81 1.00
40.00 0.30 1060.90 954.81 1.00
40.00 0.35 795.67 835.46 0.30
40.00 0.35 795.67 835.46 0.20
25.00 0.18 1989.18 1074.16 0.20
25.00 0.35 #DIV/0! #DIV/0! 1.50
30.00 0.20 #DIV/0! #DIV/0! 0.50
10.00 0.05 #DIV/0! #DIV/0! 1.00
40.00 0.25 #DIV/0! #DIV/0! 1.00
25.00 0.10 #DIV/0! #DIV/0! 0.30
20.00 0.08 #DIV/0! #DIV/0! 0.20
100.00 0.05 #DIV/0! #DIV/0! 0.20
25.00 0.25 994.59 745.94 1.50
Page 12
Milling
18.00 0.04 1909.61 229.15 0.50
60.00 0.40 954.81 1145.77 1.50
35.00 0.30 696.21 626.59 0.50
16.00 0.10 1603.87 481.16 1.00
35.00 0.30 696.21 626.59 1.00
50.00 0.35 1591.34 1670.91 0.30
18.00 0.08 1432.21 343.73 0.20
40.00 0.30 1060.90 954.81 1.50
20.00 0.20 1591.34 954.81 0.50
10.00 0.05 #DIV/0! #DIV/0! 1.00
60.00 0.40 954.81 1145.77 1.50
30.00 0.20 1591.34 954.81 0.50
30.00 0.20 1591.34 954.81 1.00
45.00 0.30 716.10 644.49 1.00
25.00 0.10 #DIV/0! #DIV/0! 0.30
20.00 0.08 #DIV/0! #DIV/0! 0.20
100.00 0.05 #DIV/0! #DIV/0! 0.20
60.00 0.40 954.81 1145.77 1.50
45.00 0.35 895.13 939.89 0.50
45.00 0.35 895.13 939.89 1.00
50.00 0.35 994.59 1044.32 1.00
Page 13
Milling
30.00 0.25 1591.34 1193.51 0.30
30.00 0.25 1591.34 1193.51 0.20
100.00 0.05 5304.48 795.67 0.20
20.00 0.20 530.45 318.27 1.50
18.00 0.08 1909.61 458.31 0.50
10.00 0.08 795.67 190.96 1.00
40.00 0.25 1060.90 795.67 1.00
20.00 0.10 1060.90 318.27 0.30
20.00 0.08 #DIV/0! #DIV/0! 0.20
100.00 0.05 #DIV/0! #DIV/0! 0.20
50.00 0.45 994.59 1342.70 1.50
40.00 0.35 1060.90 1113.94 0.50
35.00 0.30 928.28 835.46 1.00
35.00 0.30 928.28 835.46 1.00
35.00 0.30 928.28 835.46 0.30
35.00 0.30 928.28 835.46 0.20
35.00 0.30 928.28 835.46 0.20
35.00 0.30 928.28 835.46 0.20
100.00 0.05 #DIV/0! #DIV/0! 0.20
20.00 0.20 795.67 477.40 1.50
30.00 0.25 288.29 216.22 0.50
30.00 0.25 1591.34 1193.51 1.50
Page 14
Milling
40.00 0.35 1273.07 1336.73 1.50
20.00 0.10 1273.07 381.92 0.50
15.00 0.05 1909.61 286.44 1.00
30.00 0.25 1591.34 1193.51 1.50
45.00 0.40 716.10 859.33 1.50
45.00 0.30 716.10 644.49 0.50
40.00 0.30 1591.34 1432.21 1.00
45.00 0.20 1432.21 859.33 1.00
25.00 0.10 1326.12 397.84 0.30
30.00 0.30 954.81 859.33 0.20
100.00 0.05 #DIV/0! #DIV/0! 0.20
Page 15
Milling
Approached Length (mm)
Metal Removal Rate Cycle time for No of passes

(mm^3/min) each pass (min) Required
t ( D-t) Sq.root (t (D-t) )
7161 15.75 3.97 0.26 15.00
1719 4.75 2.18 0.24 30.00
2148 2.00 1.41 0.52 4.00
#DIV/0! -0.04 Err:502 Err:502
17545 21.75 4.66 0.25 51.00
8355 11.00 3.32 0.21 143.00
2864 4.00 2.00 1.04 40.00
8355 7.00 2.65 0.15 52.00
412 0.81 0.90 0.02 560.00
306 0.96 0.98 0.99 5.00
306 0.96 0.98 0.56 5.00
668 1.16 1.08 1.12 13.00
344 0.96 0.98 0.29 24.00
306 0.96 0.98 0.08 15.00
#DIV/0! -0.04 Err:502 Err:502
20051 21.75 4.66 0.20 100.00
5013 7.75 2.78 0.21 33.00
10025 15.00 3.87 0.23 162.00
2292 2.00 1.41 0.68 60.00
Page 16
Milling
955 0.50 0.71 0.21 119.00
9548 7.00 2.65 0.50 30.00
#DIV/0! -1.00 Err:502 Err:502
7161 15.75 3.97 0.26 27.00
2387 2.75 1.66 0.42 10.00
#DIV/0! -0.04 Err:502 Err:502
25780 27.75 5.27 0.26 90.00
2864 3.75 1.94 0.99 18.00
11458 11.00 3.32 0.17 150.00
11458 11.00 3.32 0.59 60.00
4010 4.71 2.17 0.25 24.00
2673 3.16 1.78 0.22 36.00
859 0.76 0.87 0.08 195.00
#DIV/0! -2.25 Err:502 Err:502
#DIV/0! -0.25 Err:502 Err:502
#DIV/0! -1.00 Err:502 Err:502
#DIV/0! -1.00 Err:502 Err:502
#DIV/0! -0.09 Err:502 Err:502
#DIV/0! -0.04 Err:502 Err:502
#DIV/0! -0.04 Err:502 Err:502
8951 9.75 3.12 0.12 32.00
Page 17
Milling
344 1.25 1.12 0.19 9.00
34373 27.75 5.27 0.25 104.00
5013 7.75 2.78 0.31 126.00
1528 2.18 1.47 0.40 48.00
10025 15.00 3.87 0.35 70.00
5013 2.91 1.71 0.61 40.00
275 0.76 0.87 0.05 208.00
17187 15.75 3.97 0.29 32.00
1910 1.75 1.32 0.05 150.00
#DIV/0! -1.00 Err:502 Err:502
34373 27.75 5.27 0.25 100.00
2864 2.75 1.66 0.05 1280.00
5729 5.00 2.24 0.04 160.00
12890 19.00 4.36 0.34 64.00
#DIV/0! -0.09 Err:502 Err:502
#DIV/0! -0.04 Err:502 Err:502
#DIV/0! -0.04 Err:502 Err:502
34373 27.75 5.27 0.27 100.00
7519 7.75 2.78 0.28 120.00
15038 15.00 3.87 0.12 110.00
16709 15.00 3.87 0.26 168.00
Page 18
Milling
2148 1.71 1.31 0.15 240.00
1432 1.16 1.08 0.10 120.00
955 1.16 1.08 0.12 120.00
5729 15.75 3.97 0.12 20.00
687 1.25 1.12 0.08 24.00
764 3.00 1.73 0.19 24.00
9548 11.00 3.32 0.05 160.00
573 1.71 1.31 0.19 9.00
#DIV/0! -0.04 Err:502 Err:502
#DIV/0! -0.04 Err:502 Err:502
32225 21.75 4.66 0.18 120.00
6684 5.75 2.40 0.19 104.00
10025 11.00 3.32 0.89 12.00
10025 11.00 3.32 0.11 16.00
3008 3.51 1.87 0.10 32.00
2005 2.36 1.54 0.12 16.00
2005 2.36 1.54 0.15 20.00
2005 2.36 1.54 0.16 16.00
#DIV/0! -0.04 Err:502 Err:502 16.00
5729 9.75 3.12 0.16 54.00
3581 16.31 4.04 0.17 24.00
10742 6.75 2.60 0.34 35.00
Page 19
Milling
20051 12.75 3.57 0.07 80.00
955 2.25 1.50 0.03 24.00
716 1.50 1.22 0.12 16.00
10742 6.75 2.60 0.67 30.00
25780 27.75 5.27 0.31 100.00
6445 9.75 3.12 1.31 40.00
11458 7.00 2.65 0.59 12.00
8593 9.00 3.00 0.25 300.00
716 1.71 1.31 0.06 140.00
1719 1.96 1.40 0.25 60.00
#DIV/0! -0.04 Err:502 Err:502
Page 20
Milling
For Drilling
Total Cycle Time
Cycle time (min) Remarks
(min)
Hole dia
3.92 16 3.4544
7.06 5.588
2.08 13.06
12.53 138 2.2606
29.33 173 5.461
41.51 2.5
8.00 2.8448
11.19
4.93
132.92
2.80
14.58
6.89
1.17
20.31 149 3.5814
7.03 164 3.4544
36.64 5.588
40.96
144.38
Page 21
Milling
144.38
24.51
14.93
7.06 14 3.5814
4.17 5.969
11.22
23.59 138 2.413
17.83 165 3.5814
25.75 3.8608
35.12 7.3406
131.80
5.99
8.01
15.51
Err:502 Err:502
Err:502 Err:502
Err:502
Err:502
Err:502
Err:502
Err:502
Err:502
3.79 6 6.35
5.53 Page 22
Milling
1.74 5.53 6
25.89 152 7.1374
39.38 183 3.2639
19.40 4.0386
24.55 143.59
24.46
9.90
9.35 19 6.5278
8.06 20 3.2639
17.41
4.2926
24.90 118
65.22 165
6.10
21.49
117.70
26.64 198 7.1374
33.43 238 7.1374
13.50 4.0386
43.87 14.2748
180.10
Page 23
Milling
180.10
36.58 3.2639
12.11
13.96
2.36 20 4.9276
1.82 22 8.89
4.45 6.604
7.35 11.9126
17.71
1.73
21.87 72 3.9624
19.54 80 3.5814
10.67 3.4544
1.71 5.969
3.17
64.39
1.86
2.99
2.58
8.74 25
4.12 28
24.67
11.81
Page 24
24.67
Milling
5.90 9
0.80 11
8.64
1.95
20.20 20
20.20
30.87 189
52.22 256
7.05
76.15
189.44
8.18
14.97
Page 25
Milling
For Drilling
length of hole Cutting speed feed spindle speed
4.6 12 0.04 1105.61
1.8 12 0.04 683.47
10 0.03 #DIV/0!
10 0.03 #DIV/0!
6.1722 10 0.02 1407.89
1.778 15 0.025 874.20
8 10 0.03 1118.77
6.096 15 0.015 1678.16
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
21.59 15 0.035 1333.01
21 15 0.035 1382.01
1.6 15 0.03 854.34
10 0.03 #DIV/0!
Page 26
Milling
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
5 12 0.03 1066.41
1.6 12 0.03 639.84
10 0.03 #DIV/0!
50 18 0.01 2374.15
4 15 0.025 1333.01
3 12 0.02 989.23
1.6 10 0.04 433.57
7 0.02 #DIV/0!
7 0.025 #DIV/0!
15 0.04 #DIV/0!
8 0.025 #DIV/0!
10 0.03 #DIV/0!
10 0.03 #DIV/0!
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
3.81 12 0.04 601.45
Page 27
Milling
8 0.025 #DIV/0!
8 12 0.06 535.10
25 15 0.03 1462.68
25 15 0.04 1182.10
10 0.03 #DIV/0!
7 0.02 #DIV/0!
7 0.025 #DIV/0!
3.048 12 0.04 585.07
3.048 12 0.015 1170.14
1.6 10 0.015 741.44
15 0.04 #DIV/0!
8 0.025 #DIV/0!
10 0.03 #DIV/0!
10 0.03 #DIV/0!
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
4.064 10 0.04 445.92
5.08 10 0.04 445.92
5 12 0.025 945.68
1.5748 10 0.05 222.96
Page 28
Milling
26.162 7 0.02 682.58
7 0.025 #DIV/0!
10 0.03 #DIV/0!
4.318 15 0.015 968.83
2.413 10 0.03 358.01
9.525 10 0.03 481.93
7.5438 10 0.03 267.17
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
1.524 15 0.018 1204.83
1.524 15 0.018 1333.01
2.54 15 0.018 1382.01
1.5 15 0.025 799.80
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
15 0.04 #DIV/0!
8 0.025 #DIV/0!
Page 29
Milling
15 0.04 #DIV/0!
8 0.025 #DIV/0!
10 0.03 #DIV/0!
15 0.04 #DIV/0!
15 0.04 #DIV/0!
8 0.025 #DIV/0!
10 0.03 #DIV/0!
10 0.03 #DIV/0!
7 0.02 #DIV/0!
7 0.025 #DIV/0!
10 0.03 #DIV/0!
Page 30
Milling
Approach length CT No of Holes Total CT
1.7272 0.143 8 1.14
2.794 0.168 8 1.34
0 #DIV/0!
0 #DIV/0!
Total Cycle Time (min) 2.49

1.1303 0.259 4 1.04
2.7305 0.206 4 0.83
1.4224 0.224 7 1.57
1.4224 0.30 7 2.09
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

1.7907 0.501 7 3.51
1.7272 0.470 2 0.94
2.794 0.171 2 0.34
0 #DIV/0!
Page 31
Milling
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

1.7907 0.212 7 1.49
2.9845 0.239 7 1.67
0 #DIV/0!

1.2065 2.157 1 2.16
1.7907 0.174 8 1.39
1.9304 0.249 4 1.00
3.6703 0.30 4 1.22
0 #DIV/0!
0 #DIV/0!

0 #DIV/0! #DIV/0!
0 #DIV/0! #DIV/0!
0 #DIV/0! #DIV/0!
0 #DIV/0! #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
Total Cycle Time (min) #DIV/0!

3.175 0.290 2 0.58
Page 32
Milling
0 #DIV/0!

3.5687 0.360 8 2.88
1.63195 0.607 2 1.21
2.0193 0.571 8 4.57
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

3.2639 0.270 2 0.54
1.63195 0.267 2 0.53
2.1463 0.337 2 0.67

0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

3.5687 0.428 10 4.28
3.5687 0.485 8 3.88
2.0193 0.297 14 4.16
7.1374 0.78 2 1.56
Page 33
Milling
1.63195 2.04 2 4.07
0 #DIV/0!
0 #DIV/0!

2.4638 0.467 2 0.93
4.445 0.639 2 1.28
3.302 0.40 1 0.40
5.9563 1.93 0.00
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

1.9812 0.162 16 2.59
1.7907 0.138 8 1.11
1.7272 0.172 11 1.89
2.9845 0.22 11 2.47
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

0 #DIV/0!
0 #DIV/0!
Page 34
Milling

0 #DIV/0!
0 #DIV/0!
0 #DIV/0!

0 #DIV/0!

0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
0 #DIV/0!
Page 35
Cutting Parameters for mat.
Cutting Parameters for Milling
For HSS
S No RM Grade
Cutting Speed
Feed (mm/min)
(SF/min)
1 Aluminium 600.00
2 Brass 175.00
3 Delrin 400.00
4 Polucarbonate 300.00
5 SS (303) 80.00
6 Steel (4140) 70.00
Cutting Parameters for Drilling
For Drilling For Countersink

S No RM Grade
Cutting Speed Cutting Speed
(SF/min) (SF/min)
1 Aluminium 300.00 200
2 Brass 120.00 90
3 Delrin 150.00 100
4 Polucarbonate 240.00 160
5 SS (303) 50.00 35
6 Steel (4140) 90.00 60
Page 36
7 Bronze (High Tensile) 100.00
8 Cast Iron (Soft) 100.00
9 Cast Iron (Med. Hard) 80.00
10 Cast Iron (High Hard) 20.00
11 Hastelloy 20.00
12 Inconel 25.00
13 Magnesium & Its Alloys 300.00
14 Monel 25.00
15 High Nickel Steel 50.00
16 Mild Steel (0.2 to 0.3 C) 100.00
17 Steel (0.4 to 0.5 C) 60.00
18 40.00
Tool Steel
19 Forgings 40.00
20 Steel Alloys (300 – 400 Brinell) 30.00
21 Heat Treated Steel (35 – 40 Rockwell C) 20.00
25 Stainless Steel Free Machining 40.00
26 Stainless Steel Work hardened 20.00
27 Titanium Alloys 20.00
Cutting Parameters for Drilling

Page 37
Tool dia 0.125” to

Tool dia <0.125”
0.25”
S No RM Grade
Cutting Feed Cutting Feed
(Inch/Rev) (Inch/Rev)
Milling
1 Aluminium 0.0020 0.0020
2 Brass 0.0010 0.0020
3 Delrin 0.0020 0.0020
4 Polucarbonate 0.0010 0.0030
5 SS (303) 0.0005 0.0010
6 Steel (4140) 0.0005 0.0005
7 Brass (Soft) 0.004 – 0.01
8 Brass (Hard) 0.004 – 0.01
9 Bronze (Soft) 0.004 – 0.01
10 Bronze (Hard) 0.004 – 0.01
11 Copper 0.004 – 0.01
12 Steel 100 BRN 0.004 – 0.00
13 Steel 200 BRN 0.004 – 0.00
14 Steel 300 BRN 0.003 – 0.00
15 Steel 400 BRN 0.002 – 0.00
16 Steel 500 BRN 0.001 – 0.00
17 Steel (Free machining) 0.002 – 0.00
18 Steel (hard) 0.002 – 0.00
19 Titanium (Soft) 0.002 – 0.00
Page 38
20 Titanium (Hard) 0.001 – 0.00
Drilling 0.0020 0.0040
Reaming 0.0050 0.0070
Page 39
Table feed (fm) = fxNxn
F – feed from chart

N – Spindle speed n
– No.of teeth
Spindle speed= K * V / 3.142 * Dt
K=12 or 60000 or
1000
D – Cutter Dia V
– Cutting Speed
Cycle time= L + LA / fm
L – Length of
component LA
– Length allowance
fm – Table feed
Length allowance= Sq.rt t(D-t)
D – Cutter Dia
t – Depth of cut
MRR= fm x W x t
Page 40
Milling
For Carbide
Cutting Speed (SF/min) Feed (mm/min)
800.00
175.00
800.00
500.00
300.00
350.00
Drilling
For Tapping
For Reamer
(HSS Tape)
Cutting Speed
Cutting Speed (SF/min)
(SF/min)
70-90 and 50-70 for

150.00
Al Aly
66.00 60-100
75.00 100
120.00 100
25.00 35
45.00 35
Page 41
30-40
60-80
50-60
30-60
15-30
20-40
50-70
10-12
50-70
30-50
20-40
20-30
15-25
15-25
10-15
10-20
15-25
60-100
ers for Drilling

Page 42
Tool dia 0.25” to Tool dia 0.5” to

0.50” 1.0”
Cutting Feed
Cutting Feed (Inch/Rev)
(Inch/Rev)
ng
0.0050 0.0060
0.0020 0.0040
0.0050 0.0060
0.0060 0.0080
0.0020 0.0030
0.0010 0.0020
0.004 – 0.012
0.004 – 0.010
0.004 – 0.012
0.004 – 0.010
0.004 – 0.012
0.004 – 0.006
0.004 – 0.005
0.003 – 0.004
0.002 – 0.003
0.001 – 0.002
0.002 – 0.005
0.002 – 0.004
0.002 – 0.005
Page 43
0.001 – 0.003
0.0050 0.0100
0.0090 0.0120
Page 44
S No Process Term Unit Formula
40I / (Tm^1.23)
Metal Removal I= Current in Amphere
1 Electrical Discharge Machining Rate CC/Min Tm=Melting temperature of work piece in °C
Metal Removal
2 Chemical Machining Rate MM/Min 0.0025 to 0.1
C*I* h
C= specific (material) removal rate (e.g.,0.2052
cm3/amp-min for nickel);
I= current (amp);
h= current efficiency (90–100%)
3 Electro-Chemical Machining CC/Min)
4
Metal removal
Rate (mm^3 / Tolerance
S No Process Name Min) (mm) Surface Finish CLA (Microns)
1 Ultrasonic Machining 300 0.0075 0.2-0.5
2 Abrasive Jet Machining 0.8 0.05 0.5-1.2
3 Electro Chemical Machining 1500 0.05 0.1-2.5
4 Chemical Machining 15 0.05 0.4-2.5
5 Electrical Discharge Machining 800 0.015 0.2-12.5
6 Electron Beam Machining 1.6 0.025 0.4-2.5
7 Laser Beam Machining 0.1 0.025 0.4-1.25
8 Plasma Arc Machining 75000 0.125 Rough
9 Milling 50000 0.05 0.4-5.0
1500000
1000
16.6666667
Formula Remarks
mphere The volume of the material removed per spark discharge

mperature of work piece in °C is typically in the range of 10-6 to 10-6 mm3
• High surface finish (up to 25 µm in) can be achieved by ECM

process.
• Complex geometrical shapes in high-strength materials
terial) removal rate (e.g.,0.2052 particularly in the aerospace industry for the mass production
or nickel); of turbine blades, jet-engine parts and nozzles can be
); machined repeatedly and accurately.
ency (90–100%) • Deep holes can be made by this process.
600
Surface Corner
Damage Depth Radius Power
e Finish CLA (Microns) (microns) (mm) (watts)
0.2-0.5 25 0.025 2400
0.5-1.2 2.5 0.1
0.1-2.5 5 0.025 100000
0.4-2.5 50 0.125
0.2-12.5 125 0.025 2700
0.4-2.5 250 2.5 150
0.4-1.25 125 2.5 2
Rough 500 - 50000
0.4-5.0 25 0.05 3000
3.5
2100
0.28
117.6
85
85
1200
3503
4204

Milling Cycle-Time Calculation

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Milling

1 76009914-001 Cover, Tranformer Al Alloy 6061-T6 100 x 100 x 6.35

Heatsink, TADS/PNVS power supply

Cover, tactical, programmable power

4 76009953 Plate, Access, PSI Al Alloy 6061-T6 100 x 90 x 6.35

5 76009952-001 Cover, RPS Al Alloy 6061-T651 220 x 160 x 50.8

7 76009954 Bracket Assy, Connector Mounting

7 76009954 Bracket Assy, Connector Mounting Al Alloy 6061-T651 95 x 31.75 x 6.35

11.1.1 - Top panel Al Alloy 6061-T651 280 x 230 x 31.75

11.5.1 - AFT Panel Al Alloy 6061-T651 300 x 190 x 44.5

13 76009951 Cover Front PSI Al Alloy 6061-T651 240 x 177.8 x 12.7

14 76009948 Bracket, Cable Mount Al Alloy 6061-T651 105 x 72 x 5.08

15 76009944 Cover, Access, Rear, VPC Al Alloy 6061-T651 95 x 25.4 x 6.35

16 76009918 Cover, Access, Rear, VPC Al Alloy 6061-T651 235 x 190 x 3

Chassis, Brazement, Power AID

Milling 1.5 3 130

Milling 3.175 3 193.04

Milling 2.5 3 33.655

25.00 0.20 663.06 397.84 1.50

20.00 0.18 636.54 343.73 0.50

15.00 0.15 1591.34 716.10 1.00

100.00 0.05 #DIV/0! #DIV/0! 0.20

35.00 0.35 696.21 731.02 1.50

35.00 0.25 928.28 696.21 1.00

20.00 0.15 1273.07 572.88 1.00

35.00 0.25 1392.43 1044.32 1.00

18.00 0.08 1909.61 458.31 0.30

20.00 0.08 1273.07 305.54 0.20

20.00 0.08 1273.07 305.54 0.20

35.00 0.10 1856.57 556.97 0.20

18.00 0.10 1145.77 343.73 0.20

20.00 0.08 1273.07 305.54 0.20

20.00 0.08 #DIV/0! #DIV/0! 0.20

40.00 0.35 795.67 835.46 1.50

35.00 0.30 696.21 626.59 0.50

35.00 0.30 696.21 626.59 1.00

20.00 0.12 2121.79 763.84 1.00

20.00 0.05 4243.58 636.54 1.00

40.00 0.25 1591.34 1193.51 1.00

20.00 0.12 #DIV/0! #DIV/0! 1.00

25.00 0.20 663.06 397.84 1.50

25.00 0.20 1326.12 795.67 0.50

100.00 0.05 #DIV/0! #DIV/0! 0.20

45.00 0.40 716.10 859.33 1.50

40.00 0.15 1591.34 716.10 0.50

40.00 0.30 1060.90 954.81 1.00

40.00 0.30 1060.90 954.81 1.00

40.00 0.35 795.67 835.46 0.30

40.00 0.35 795.67 835.46 0.20

25.00 0.18 1989.18 1074.16 0.20

25.00 0.35 #DIV/0! #DIV/0! 1.50

30.00 0.20 #DIV/0! #DIV/0! 0.50

10.00 0.05 #DIV/0! #DIV/0! 1.00

40.00 0.25 #DIV/0! #DIV/0! 1.00

25.00 0.10 #DIV/0! #DIV/0! 0.30

20.00 0.08 #DIV/0! #DIV/0! 0.20

100.00 0.05 #DIV/0! #DIV/0! 0.20

25.00 0.25 994.59 745.94 1.50

18.00 0.04 1909.61 229.15 0.50

60.00 0.40 954.81 1145.77 1.50

35.00 0.30 696.21 626.59 0.50

16.00 0.10 1603.87 481.16 1.00

35.00 0.30 696.21 626.59 1.00