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

Calculation of cutting forces, boring

(simplied)

Example calculation:

Boring tool 80 mm; Z = 5; pre-drilled 72 mm = 90

72 pre-drilled

80

Material: EN-GJL-250 kc1.1* = 1160 mc = 0.26 vc 200 m/min fz= 0.2 mm Blunting 30 % Result

Basic formula 1. Spindle speed

Calculation

Vc 1000 n = D (D d) ap = 2 A = ap f z

200 1000 n = 80 (80 72) ap = 2 A = 4 mm 0,2 mm 5

n = 800 1/min

2. Cutting depth

ap = 4 mm

3. Cutting cross section

A = 4 mm2

4. Chipping thickness

h = fz sin kc1.1 kc = h mc

h = 0,2 mm sin90 1160 kc = 0,2 0,26

h = 0,2 mm

5. Specic cutting force without blunting factor

kc = 1763 N/mm2
with 30 % blunting: 1763 N/mm2 1,3 = 2292 N/mm2

6. Cutting force

Fc = A kc = b h kc dm Mc = Fc 2 2 n Mc Pc = 60s

Fc = 4 mm2 2292 N/mm2 0,076 m Mc = 9167,3 N 2 2 800 min-1 348,3 Nm Pc = 60s

Note: The efficiency of the main spindle drive is not taken into account. Appropriate power calculations can be made by MAPAL.

Fc = 9,17 kN

7. Cutting torque dm = average diameter in metres

Mc = 348,3 Nm

8. Cutting power

Pc = 29,2 kW

* Value for cutting force calculation, WTO GmbH

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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 There follow two spindle speed/power diagrams. The number of teeth and cutting parameters are to be dened as a function of the machine. In the example calculation the machine with the motor spindle is unsuitable, as here at a spindle speed of 800 1/min a torque of 187 Nm and a power of approx. 20 kW is achieved (Figure 1). Motor spindle (Figure 1)
Torque (Nm) Power (kW) 35 kW 100% 630 400 200 160 100 40 10 5 1000 1600 4000 10.000 40 30 20 10 8 5 3,15 2 0,6 1000 1600 4000 10.000 0,6 187 Nm 100% 40 30 20 10 8 5 3,15 2

Torque curve in Nm Power curve in kW Line to assist on reading the diagram

Spindle speed (1/min)

Solution: Either reduce number of teeth, reduce cutting speed and feed, divide cut between two tools or select more powerful machine (e.g. with geared spindle, (Figure 2).

Geared spindle (Figure 2)

Torque (Nm) Power (kW) 42 kW 100% 630 400 200 160 100 40 10 5 400 Nm 100%

The example diagrams are shown in a simplied form.

Spindle speed (1/min)

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Technical appendix