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INDEX
Page 1
INDEXSURFACE FINISH
TOLERANCE FINDER
QTY CHECK
CYCLE TIME CHECK
CUTTING SPEED
POWER CALCULATION
FORMING PRESURE
Note: This all calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for
tool design.
INDEX
Page 2
INDEXSPRING PRESURE
CUTTING FORCE
TOLERANCE
THREADING
AIR CYLINDER FORTCE
BEND VARIABLE
#POWER & TORQUE
Note: This all calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for
tool design.
INDEX
Page 3
SCREW STRENTH
WEIGHT CALCULATION
SPOT DRILL DEPTH
DEPTH OF CUT
MACHINE POWER(kw)
THREAD DEPTH CALCULATION
Powered by
SENKAMS SOLUTIONS LTD.,
THREAD DEPTH CALCULATION
Page 4
THREAD DEPTH CALCULATIONINPUT DETAILS
Thread pitch (mm) 1.25Thread depth (ap) 0.783No. of passes (nap) 15 Note:
1) Minimum entered 2 passes.RESULTS 2) Maximum entered 50 passes.
1st pass, radial infeed 0.115 0.1152nd pass, radial infeed 0.209 0.0953rd pass, radial infeed 0.296 0.0874th pass, radial infeed 0.363 0.0675th pass, radial infeed 0.419 0.0566th pass, radial infeed 0.468 0.0497th pass, radial infeed 0.513 0.0458th pass, radial infeed 0.554 0.0419th pass, radial infeed 0.592 0.03810th pass, radial infeed 0.628 0.03611th pass, radial infeed 0.662 0.03412th pass, radial infeed 0.694 0.03213th pass, radial infeed 0.725 0.03114th pass, radial infeed 0.755 0.03015th pass, radial infeed 0.783 0.02816th pass, radial infeed 0.81117th pass, radial infeed 0.83718th pass, radial infeed 0.86319th pass, radial infeed 0.88820th pass, radial infeed 0.91321st pass, radial infeed 0.93622nd pass, radial infeed 0.95923rd pass, radial infeed 0.98224th pass, radial infeed 1.00425th pass, radial infeed 1.02626th pass, radial infeed 1.04727th pass, radial infeed 1.06828th pass, radial infeed 1.088
GOTO INDEX
THREAD DEPTH CALCULATION
Page 5
29th pass, radial infeed 1.10830th pass, radial infeed 1.12731st pass, radial infeed 1.14732nd pass, radial infeed 1.16633rd pass, radial infeed 1.18434th pass, radial infeed 1.20335th pass, radial infeed 1.22136th pass, radial infeed 1.23937th pass, radial infeed 1.25638th pass, radial infeed 1.27339th pass, radial infeed 1.29140th pass, radial infeed 1.30741st pass, radial infeed 1.32442nd pass, radial infeed 1.34143rd pass, radial infeed 1.35744th pass, radial infeed 1.37345th pass, radial infeed 1.38946th pass, radial infeed 1.40447th pass, radial infeed 1.42048th pass, radial infeed 1.43549th pass, radial infeed 1.45050th pass, radial infeed 1.465
THREAD DEPTH CALCULATION
Page 6
1) Minimum entered 2 passes.2) Maximum entered 50 passes.
SURFACE FINISH
Page 7
Surface Finish Rmax=(fn²/8*r£)*1000
Feed (fn)
Ra (normal insert)
Ra (wiper insert)
Surface Finish (feed calculation)
Ra
Feed (fn)
Tool nose radius-r£
Tool nose radius-r£
GOTO INDEX
SURFACE FINISH
Page 8
Surface Finish Rmax=(fn²/8*r£)*1000
0.2
0.4
12.500
6.250
Surface Finish (feed calculation)
0.8
0.40.051
SURFACE FINISH
Page 9
N12 50
N11 25
N10 12.5
N9 6.3
N8 3.2
N7 1.6
N6 0.8
N5 0.4
N4 0.2
N3 0.1
N2 0.05
N1 0.025
QTY CHECK
Page 10
QUANTITY CHECK
Working days/Month 30 daysworking hors/shift 5.0 hrsNumber of shift 1Cycle time / comp. 5 minutesTotal hrs/ day 5Total hrs/ Month 150Minutes/Month 9000Qty / Month 1800 nos
GOTO INDEX
CYCLE TIME CHECK
Page 11
CYCLE TIME CHECK
Working days/Monthworking hors/shiftNumber of shiftQty / MonthTotal hrs/ dayTotal hrs/ Monthminutes/Month
Cycle time / comp.
GOTO INDEX
CYCLE TIME CHECK
Page 12
CYCLE TIME CHECK
30 days7 hrs
210 nos
13390
234002340 min
140400 seconds
CUTTING SPEED
Page 13
CUTTING SPEED
Dia. of component
Spindle RPM
Feed (Fn)-mm/rev
Cutting speed (Vc)
Feed (Fn)-mm/min
Spindle RPMDia. of componentCutting speed (Vc)Spindle RPM
GOTO INDEX
CUTTING SPEED
Page 14
CUTTING SPEED
Ø 50.0
1000
0.2 mm/rev
Vc=157.08
mm/min=200.00
Spindle RPMØ 20.0
Vc=120.001909.859
POWER CALCULATION
Page 15
POWER CALCULATIONCUTTING SPEED, V m/minFEED RATE, f mm/revDEPTH OF CUT, d mmPOWER CONSTANT, KpFEED FACTOR FOR POWER CONSTANTS, CTOOL WEAR FACTOR, WMACHINE TOOL EFFICIENCY FACTOR, EMETAL REMOVAL RATE , Q cm³/sPOWER AT THE CUTTING TOOL, Pc kWPOWER AT THE MOTOR, Pm kW
GOTO INDEX
POWER CALCULATION
Page 16
POWER CALCULATION1800.5
51.69
1.30.94
0.87.50
15.4919.36
POWER & TORQUE
Page 17
Power Required W = Vc x f x Dp x Ps /( 6000 * E)
Cutting force - Fc= f x Dp x Ps / E
Cutting Torque - Tc = Fc x Dc/200
W- Power in KW Fc - Cutting Force Kg Tc - Cutting torque ( Nm ) V c - Cutting Speed in ( m/ min ) f - Feed in ( mm/rev )Dp - Depth of Cut in (mm) Ps - Specifica cutting energy ( kg/mm2 )E - Efficiency (0.8)Dc- Diameter of cutting ( mm )
Cutting force - Fc= f x Dp x Ps / E
Cutting Dia mm DP-mm 440 200 0.4 3 250 0.8 12.5
80 160 0.3 5 250 0.8 12.580 160 0.3 5 250 0.8 12.580 160 0.3 5 250 0.8 12.5
Torque Available Power ( Cont Power ( 30 min) Rpm Torque (100%) Torque (60 %)
18.5 22 200 883.375 1050.5
Ps for Steel 250 kg /mm2 Ps for Cat iron 210 Kg/mm2
Cutting Speed Vc ( m/min )
Feed ( mm/ rev )
Specific Cutting Energy KG /mm2 Efficiency
Power Req KW
POWER & TORQUE
Page 18
#INDEX
POWER & TORQUE
Page 19
Rpm144.7596989 300 825 573 1055.542
636.942675159 375 187.5 179.922 239.896636.942675159 375 187.5 179.922 239.896636.942675159 375 187.5 179.922 239.896
``
Cutting Force kg
Req Torque NM
Available Torque 100%
Available Torque 30 min
SPRING PRESURE
Page 20
Spring Pressure CalculatorLIGHT DUTY MEDIUM DUTY HEAVY DUTY EXTRA HEAVY DUTY
Free Length of Spring= 2.000 2.000 2.000 2.000Spring Force / .100"= 20 66 154 197
Preload= 0.125 0.125 0.125 0.125Travel= 0.125 0.125 0.125 0.125
Total Travel: 0.250 0.250 0.250 0.250% Compression: 13% 13% 13% 13%
Force / spring: 50 165 385 493
# of Springs= 10 10 10 10
Total Force: 500 1650 3850 4925
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
GOTO INDEX
SPRING PRESURE
Page 21
TONS LBS245 490000
19600
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
CUTTING FORCE
Page 22
Cutting Parameters
INPUT DATATOOL NUMBER 1PART NUMBER 2
Mild Steel Semi-hard MildCut Length= 25.000 25.000 25.000
Stock Thickness= 0.079 0.079 0.079Ultimate Shear Strength= 40,000 35,000 55,000
Cutting Force Required RESULTLBS: 79,000 69,125 108,625
TONS: 40 35 54
Stripping Force Required8% 6,3205% 3,9503% 2,370
Use The "Spring Pressure" Calculator To Determine The Required Number of Springs
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
GOTO INDEX
CUTTING FORCE
Page 23
Mild Stainless Tough Stainless25.000 25.0000.079 0.079
80,000 120,000
158,000 237,000 79 119
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
TOLERANCE
Page 24
Tolerance Transformation
DEVIATION TOLERANCE SYMETRIC TOLERANCEPlus= 2.00
Nominal= 100.00 Nominal 101.50 ± 1.50Minus= 1.00
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using
this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
GOTO INDEX
THREADING
Page 25
Thread CalculatorsFinds useful thread data.
ENGLISH TAP DRILLOUTSIDE DIA : Ø 0.500
%THREAD : 0.75PITCH (THD / INCH) : 13.00
TAP DRILL =
METRIC TAP DRILLOUTSIDE DIA : Ø 16.00 MM
%THREAD : 75.00METRIC PITCH : 1.00 MM
TAP DRILL : Ø 15.03 MM Ø 0.592
NUMBER THREADSTHREAD # : 7
MAJOR DIAMETER : Ø 0.151
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown
here should be verified by qualified personnel before use for tool design.
GOTO INDEX
AIR CYLINDER FORCE
Page 26
Air Cylinder Forces & Inputs
INPUT BORE DIA 2.000 INCHESRESULTING AREA= 3.142 SQUARE INCHESFORCE PER 10 PSI= 31.42 POUNDS OF FORCE
INPUT LINE PRESSURE 50 PSIFORCE= 157.08 POUNDS
INPUT LINE PRESSURE 70 PSIFORCE= 219.91 POUNDS
INPUT LINE PRESSURE 100 PSIFORCE= 314.16 POUNDS
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be
verified by qualified personnel before use for tool design.
GOTO INDEX
AIR CYLINDER FORCE
Page 27
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be
verified by qualified personnel before use for tool design.
BEND VARIABLE
Page 28
Bend Variables
Set Radius Given Form RadiusForm Radius= R .032”
Stock Thickness= .0470”Degrees of Arc= 90.00ºNeural Axis (%)= 5%
RADIUS OF NEUTRAL AXIS: R .034”BEND DEDUCTION: .0532” 1.3505968
SET RADIUS (1.35 X STOCK): R .097”
Form Radius Given Set Radius(REFERENCE - BASED ON 8% THINNING)Set (Outside) Radius= R .060”
Stock Thickness= .0375”Degrees of Arc= 90.00ºNeural Axis (%)= 42%
RADIUS OF NEUTRAL AXIS: R .420”BEND DEDUCTION: .6598”
Form (inside) RADIUS: R .019”
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
GOTO INDEX
BEND VARIABLE
Page 29
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
CLEARENCE
Page 30
Clearance
5.0% 8.0%Material= 0.47 Clearance: 0.0235 0.0376
Hole/Feature Size: 0.1637 Clearance Hole/Feature Size: 0.2107 0.2389
Percentage Per Side= 12.00%Clearance: 0.0564
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified
personnel before use for tool design.
GOTO INDEX
CLEARENCE
Page 31
10.0% 12.0% 15.0% 18.0%0.0470 0.0564 0.0705 0.08460.2577 0.2765 0.3047 0.3329
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified
SCREW STRENTH
Page 32
Screw Strength
MINOR DIAMETER OF SCREW= 0.438 INCHESRESULTANT AREA OF SCREW 0.1503
SCREW MATERIAL TENSILE STRENGTH= 10,000 PSISCREW HOLDING POWER 1,503 LBS
NUMBER OF SCREWS= 10.00TOTAL HOLDING POWER 15,033 LBS
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before
use for tool design.
GOTO INDEX
SCREW STRENTH
Page 33
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before
use for tool design.
WEIGHT CALCULATION
Page 34
LENGTH WIDTH HEIGHT DENSITY1.000 1.000 1.000 0.284
AREA (sq. in.) THICKNESS Density36.700 0.500 0.284
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using
this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
GOTO INDEX
WEIGHT CALCULATION
Page 35
Weight0.284
Weight5.2114
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using
this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
SPOT DRILL DEPTH
Page 36
Spot Drill Depth Calculations For CNC
STD DRILL SPOT DRILLDIA 0.1250 DIA 0.1250RAD 0.0625 RAD 0.0625POINT EXTENSION 0.0376 POINT EXTENSION 0.0361
STD DRILL SPOT DRILLOVERAGE 0.0312 OVERAGE 0.0312BASE DIA 0.1250 BASE DIA 0.1250FINAL DIAMETER 0.1562 FINAL DIAMETER 0.1562RAD 0.0781 RAD 0.0781POINT EXTENSION 0.0469 POINT EXTENSION 0.0451
FACTORS118 POINT DIVIDE BY 3.3
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be
verified by qualified personnel before use for tool design.
GOTO INDEX
DEPTH OF CUT
Page 37
PL 360 (STANDARD MACHINE) 5.5/7.5kW SPINDLE MOTOR
CALCULATION FOR MAXIMUM DEPTH OF CUT FOR GIVEN MOTOR POWER
FORMULA P = (Pz x V) / (102 x 60)
DEFINITION
P - POWER (Kw)Pz - CUTTING FORCE (N-m)V - CUTTING SPEED (m/min)
FORMULA Pz = Ks x f x d x Kr x Kw x Kv
DEFINITION
Ks - SPECIFIC CUTTING RESISTANCEf - FEED (mm/rev)d - DEPTH OF CUT (mm)Kr - CORRECTION FACTOR FOR RAKE ANGLEKw - CORRECTION FACTOR FOR WEARKv - CORRECTION FACTOR FOR CUTTING SPEED
FOR EXAMPLETO CALCULATE MAXIMUM DEPTH FOR CUT FOR GIVEN MATERIAL AND POWER MOTORMATERIAL SPEC. - STEEL-S43CHARDNESS - 180 BHN TENSILE STRENGTH - 62 kg/mm sq
FORMULA Pz = Ks x f x d x Kr x Kw x Kv
Ks = 180 kg/mm SQf = 0.1d = ?Kr = 1.275 Kw = 1.3Kv = 1
Pz = 180 x 0.1 x d x 1.275 x 1.3 x 1
Pz = 29.835 x d
FORMULA P = (Pz x V) / (102 x 60)
DEFINITION
P - POWER (Kw)Pz - CUTTING FORCE (N-m)V - CUTTING SPEED (m/min)
5.5=( (29.835 x d )X(250) ) /( 102 x 60 )
FOR Kr, Kw, Ks & Kv Ref. HMT PRODUCTION TECHNOLOGY BOOK (page No. 87 to 91)
DEPTH OF CUT
Page 38
d=4.5mm
DEPTH OF CUT
Page 39
GOTO INDEX
MACHINE (kw) CALCULATION
Page 40
FEED
5.5 Steel 180 0.8 0.1 250 1.275 1.37.5 Steel 180 0.8 0.3 250 1.275 1.39 Steel 180 0.8 0.1 250 1.275 1.311 Steel 180 0.8 0.3 250 1.275 1.315 Steel 180 0.8 0.1 250 1.275 1.3
18.5 Steel 150 1.2 0.05 180 1.275 1.322 Steel 180 0.8 0.1 250 1.275 1.326 Steel 180 0.8 0.3 250 1.275 1.337 Steel 180 0.8 0.1 250 1.275 1.337 Steel 180 0.8 0.3 250 1.275 1.3
MOTOR POWER kW
MATERIAL
SPECIFIC
CUTTING
FORCE
TOOL RADIUS mm
CUTTING
SPEED
CORRECTION FACTOR FOR WEAR
CORRECTION FACTOR FOR RAKE
ANGLE
GOTO INDEX
MACHINE (kw) CALCULATION
Page 41
1 4.51 112.82 1.56251 2.05 153.85 14.06251 7.38 184.62 1.56251 3.01 225.64 14.06251 12.31 307.69 1.56251 50.60 455.38 0.2604166666671 18.05 451.28 1.56251 7.11 533.33 14.06251 30.36 758.97 1.56251 10.12 758.97 14.0625
CORRECTION FACTOR FOR
CUTTING SPEED
DEPTH OF CUT
mm
METAL REMOVAL cm3/min
SURFACE ROUGHNESS IN Ra
BASIC SIZE HOLE SHAFT
10 A9 k6
Enter the Basic Size and Tolerance grades
Enter the Basic Size and Tolerance grades
`
`
Pleae Enter the Basic Size in mm
Please select the Tolerance grade
for Hole
Please select the Tolerance grade
for Shaft
`
HOLE SHAFT316 10
10 280 10 1
315
270
#INDEX
Maximum Clearance/Interferance (Microns)
Minimum Clearance/Interferance (Microns)
Enter the Basic Size and Tolerance grades
Enter the Basic Size and Tolerance grades
`
`
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