In the process of writing "Engineering Formulas for Metalcutting", the author was asked a question: "What is the unique selling feature of your book?"

"The book provides information on formulas and their applications in concise and clearly arranged form. It can serve as valuable source of knowledge in metalcutting practice and training. This book will be especially appropriate for situations in which calculations are necessary for setting maximum productivity from machine tools".

"Can you be more specific?" asked John Carleo, Director of Publications for Industrial Press.

Two interesting cases that the author has solved during two consecutive metalcutting trade shows (WESTEC-97 and WESTEC-98), explain "specifics" of required machining power versus the machine tool available power.

Case # 1, WESTEC-97

An exhibitor of bench-type milling machines complained that he could not demonstrate milling operation because his machine stalls. He believed that the milling cutter caused the problem and blamed the cutting tool manufacturer for defective face mill. The author asked the exhibitor to provide machining conditions at which he tried to machine the workpiece. The cutting conditions were as follows:

• Diameter of the face mill 2.5 in., the number of indexable inserts 5,

• Cutting speed 600 sfm, depth of cut 0.150 in., width of cut 1.0 in.,

• Feed per tooth 0.008 in.,

• Workpiece AISI 4140 alloy steel, Rockwell hardness 48 HRC,

• Available power of the milling machine 3.0 hp.

The author calculated required power at the motor of the milling machine by formulas shown in Chapter 2. "Milling", and reveled the results. The cutting conditions selected by the exhibitor, required...