Engineering Formulas For Metalcutting

Chapter 2: Milling

OVERVIEW

Milling is one of the most common metalcutting operations in which a rotating multi-edge cutting tool removes chips from a stationary workpiece to produce flat and curved surfaces in almost any direction.

Milling operation is characterized by its kinematics, productivity, and dynamics. Parameters of kinematics and productivity include:

  1. Cutting speed

  2. Spindle speed

  3. Cutter diameter

  4. Number of inserts (teeth) in the cutter

  5. Feed per tooth (same as chip load)

  6. Feed rate (same as table feed or machine feed)

  7. Depth and width of cut

  8. Number of inserts in the cut

  9. Chip thickness and lead angle of the cutter

  10. Feed rate adjustment

  11. Cross-sectional area of uncut chip

  12. Metal removal rate

  13. Machining time with linear path of the cutter

  14. Machining time with helical interpolation

Parameters of dynamics:

  1. Tangential cutting force

  2. Torque at the cutter

  3. Machining power at the cutter

  4. Machining power at the motor

2.1 KINEMATICS AND PRODUCTIVITY

Kinematics and productivity are described by formulas showing relationships between various parameters that are required to plan milling operations using various tools: face mills, end mills, die and cavity mills, slotting cutters, thread and grooving mills. Productivity is directly proportional to cutting speed (or spindle speed), feed per tooth, feed rate, depth of cut, and width of cut.

2.1.1 Cutting Speed

Cutting speed is one of the most commonly used programmable elements for CNC milling machines and machining centers. The relationship between the cutting speed V c (dependent variable), machine spindle speed n (independent variable), and the cutter diameter D (independent variable)...

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Category: Face Mills
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