Machining

Metal Cutting Process

INT 201 Eastern Kentucky University

Lecture References: 1) 2) 3) 4) Degarmo E.P., Black J.T., Kosher R. (2003). Materials and Processes in Manufacturing, 9 th edition. Wiley Repp, V. (1994). Metalwork: Technology and Practice, 9th edition. McGraw-Hill Groover, M. (2004). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 2 nd edition. Wiley Chen, C.S. (2001) ITEC 502: Advanced Design and Manufacturing [Course]. Iowa State University

Lesson Objectives
1. REVIEW: Fundamentals of Machining
2. Identify the basic parameters associated with machining (milling)

3. Understand how these basic parameters are used to create and remove chips
4. Understand that machine parameters are directly related to type of material and the machine

Machining Fundamentals
REVIEW
Machining is a process of removing unwanted material from a workpiece in the form of chips. Making and removing chips Importance of lubricants $60 billion spent annually on metal removal operations

Machining Fundamentals
Basic machine processes

Machining Fundamentals Milling Machines

SPINDLE TRANSVERSELY TABLE LONGITUDINALLY COLUMN KNEE VERTICALLY BASE

Basic Machining Parameters

Basic Machining Parameters Cutting Speed Spindle Speed (RPM) Feed Rate Metal Removal Rate Chip Load Machine Horse Power

Basic Machining Parameters

Machining variables such as cutting speed, RPM, table feed rates, metal removal rates, and depth of cut all depend on:
Work material Tool material Specific process/equipment

Cutting Speed (SFPM)

Cutting speed is the distance a point on the circumference of the milling cutter travels in one minute Measured in Surface Feet per Minute (SFPM) Calculated at the outside diameter of the cutter

Cutting Speed (SFPM) Different cutting speeds should be used when machining different metals
With cutting speeds too fast, cutter will overheat and dulls rapidly With cutting speeds too slow, time is wasted and production costs will increase

Cutting Speed (SFPM)

Factors affecting cutting speeds in milling:
Material properties, cutting tool (HSS, carbide, cast alloy), cutting fluids

Cutting speed recommendations for various materials and tooling combinations can be found in sources including: Tooling Mfg. & Engineering Handbooks (Machinist Handbook, etc)
Suggested Cutting Speed Range SFPM 80-100 60-80 400-1000 200-300

Material Low-Carbon Steel Stainless Steel Aluminum (and its alloys) Brass

Cutting Speed Formula SFPM = ( * D * N)/12

where

SFPM = Surface Feet Per Minute = Circumference constant per inch of Diameter D = Diameter of the cutter, measured in inches N = revolutions per minute of the spindle (RPM) 12 = 12 inches per foot (conversion calculation to feet)

Cutting Speed Example

If a 2 inch dia., 6 tooth milling cutter is turning at 100 revolutions per minute (RPM), what is the calculated cutting speed of the cutter (SFPM)?

SFPM ( D N)/12 SFPM ((3.14) (2 inches) (100 RPM))/12 in/ft SFPM (628)/12 52.33surfaceft/min

Spindle Speed (RPM)

The speed of the milling machine is
measured at the spindle and is measured

in REVOLUTIONS PER MINUTE (RPM)

Finding N (RPM)

SFPM * 12 N * D
Same equation; different arrangement
SFPM = ( * D * N)/12

Determining RPM
When milling with a 3 diameter, 8 tooth milling cutter with a recommended cutting speed of 250 SFPM tooling material combination, what is the recommended RPM?
SFPM *12 250 SFPM*12 3,000 N 318.5 320 RPM *D 3.14* 3 in 9.42

Feed Rate
The linear distance moved along any machine axis, by the cutting tool in inches per minute. Feed rate in milling is determined by multiplying:
Number of teeth on the cutter Chip load per tooth Speed of the cutter (N)

Chip Load Chip Load or Feed per Tooth

The Chip Load is the amount of material removed by each tooth of the milling cutter during one revolution

Chip load recommendations for various materials and tooling combinations can be found in machining and engineering handbooks

Milling Feed Rate Formula

F = N * Ct * T
where

F = Feed rate in inches per minute N = Spindle RPM Ct = Chip Load per tooth [feed per tooth] T = Number of teeth on cutter

Calculating Feed Rate A 6 inch dia., 12 tooth milling cutter is turning at 250 RPM. The recommended chip per tooth is 0.004. What is the feed rate?
= N * Ct * T = 250 RPM * 0.004/tooth * 12 teeth

F = 12 per minute

Metal Removal Rate

Metal Removal Rate (MRR) is the volume of material removed from the work piece in one minute.
Limited to available machine power How much material is removed in 1 minute

MRR Formula MRR = W * D * F

where

MRR = Cubic inches removed per minute W = Width of Cut D = Depth of Cut F = Feed rate

MRR Graphic

Volume = In3 / min

Depth Feed Rate

Width

MRR Example
What is the MRR of a surface 3 inches wide that is to be milled with a 6 tooth milling cutter. Each depth of cut is 0.125 inches and the table feed rate is 4 inches per minute
3 Feed Rate = 4/min

.125

MRR Example
3
Feed Rate = 4/min

.125

MRR = W*D*F

MRR = (3) * (0.125) * (4 per minute) MRR = 1.5 cubic inches per minute (in3/min) of material removed

Horse Power (specific) HPs

HPs = Horse power required to remove 1 cubic inch (in3/min) of material per minute All machined materials have a HPs rating HPs is used to determine the HP required for machining. The standard HPs = 1
Materials with HPs > 1 require more than 1 HP/minute to remove 1 in3 of material Materials with HPs < 1 require less than 1 HP/minute to remove 1 in3 of material

HPs can be found in machining and engineering handbooks

Horse Power Formula

HP = HPs * MRR
where

HP = Horse Power required to make a desired cut HPs = specific Horse Power of material MRR = Material Removal Rate

HP Example
How much Horse Power is required to machine a part with a desired MRR of 3.94 in3/min and a specific Horse Power (HPs) of 1.8?

HP = HPs * MRR HP = 1.8 * 3.94 HP = 7.1

Review
What is the maximum MRR of a material with a 1.6 HPs on a 1.2 HP machine?

How much material can be removed from the same material on a 7.1 HP machine?

Review
Machining variables such as cutting speed, RPM, table feed rates, metal removal rates, and depth of cut all depend on:
Work material Tool material Specific process/equipment

WHY?