Speeds and Feeds © 2013 Project Lead The Way, Inc.Computer Integrated Manufacturing

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Text of Speeds and Feeds © 2013 Project Lead The Way, Inc.Computer Integrated Manufacturing

  • Slide 1
  • Speeds and Feeds 2013 Project Lead The Way, Inc.Computer Integrated Manufacturing
  • Slide 2
  • In This Lesson Identify common cutting tools Learn the definition of speeds and feeds Calculate cutting speeds and feed rate
  • Slide 3
  • Center Cutting End Mill Ball End Mill Non-Center Cutting End Mill Indexable Shell Mill Basic Cutting Tools
  • Slide 4
  • Combination Drill & Countersink Spotting Drill Countersink
  • Slide 5
  • 2 Flute End Mill More room for chip evacuation Used for light metals Weak, short tool life 4 Flute End Mill More cutting edges, longer tool life Used for harder metals Clogs easily in deep cuts Flutes
  • Slide 6
  • 2 Flute Center Cutting 4 Flute Center Cutting 4 Flute Non-Center Cutting Center Vs. Non-Center Cutting
  • Slide 7
  • ToolDescriptionApplication 2 Flute HSS Single End Mills for cutting aluminum 3/8 shank x 1 cutting length Facing, profiling, pocketing, slotting, roughing, and finishing 2 Flute Ball End Mill for aluminum 3/8 shank x 1 cutting length Surfacing, slotting, profiling, roughing, and finishing Milling Tools
  • Slide 8
  • ToolDescriptionApplication Countersink & De-burring tool 90 Degree Engraving, de- burring, countersink, spot drilling #3 Combined drill & countersink 90 degree Spot drilling, engraving Milling Tools
  • Slide 9
  • ToolDescriptionApplication Spotting drill 90 deg Spot drilling, engraving Milling Tools
  • Slide 10
  • Cutting Tool Material Video
  • Slide 11
  • Cutting Speed The rate of a tool measured in surface feet per minute Spindle Speed The number of revolutions per minute (rpm) that is made by the cutting tool of a machine Feed The distance advanced by the cutting tool along the length of the work for every revolution of the spindle Definitions
  • Slide 12
  • Defined in revolutions per minute (rpm) Found by dividing the cutting speed by the circumference of the tool N = CS C C = circumference CS = Cutting speed (surface ft / min) N = Spindle speed (rpm) d = Diameter (in.) / rev Spindle Feeds Formula N = CS 12 in. dd ft
  • Slide 13
  • Milling Speeds for High Speed Steel Tools MaterialCutting Speed in Surface ft/min Magnesium300 Aluminum250 Brass and Bronze150 Copper100 Cast Iron (Soft)80 Cast Iron (Hard)50 Mild Steel90 Cast Steel80 Alloy Steel (Hard)40 Tool Steel50 Stainless Steel60 Titanium50 High Manganese Steel30 Note: Double Speed for Carbide Cutting Tools Recommended Cutting Speeds
  • Slide 14
  • N = CS 12 in. dd ft What spindle speed should be used to mill aluminum with a inch end mill? Example Cutting Speed for Aluminum is 250 surface ft/min N = = 1,910 rpm 250 ft 12 in. 0.5 in. ft min rev
  • Slide 15
  • What spindle speed should be used to mill Brass with a inch end mill? Your Turn N = CS 12 in. dd ft See teacher for solution
  • Slide 16
  • f m = f t x n t x N f m = Feed rate in. f t = Feed in. n t = Number of teeth on the tool N = Spindle speed = Calculating Feed Rates CS 12 in. dd ft min tooth rev
  • Slide 17
  • Tool Feed (in./tooth/rev) MaterialFace MillSide MillEnd Mill Magnesium.005-.020.004-.010.005-.010 Aluminum.005-.020.004-.010.005-.010 Brass and Bronze.004-.020.004-.010.005-.010 Copper.004-.010.004-.007.004-.008 Cast Iron (Soft).004-.016.004-.009.004-.008 Cast Iron (Hard).004-.010.002-.006 Mild Steel.004-.010.002-.007.002-.010 Alloy Steel (Hard).004-.010.002-.007.002-.006 Tool Steel.004-.008.002-.006 Stainless Steel.004-.008.002-.006 Titanium.004-.008.002-.006 High Manganese Steel.004-.008.002-.006 Note: Double Speed for Carbide Cutting Tools Recommended Tool Feed
  • Slide 18
  • Tool Feed (in./tooth/rev) Calculate the feed rate for end milling aluminum with a 2 flute, inch HSS end mill. f m = f t n t N f t =0.005 in. Example Feed Rate tooth rev
  • Slide 19
  • n t = 2 teeth f m = 19.1 in. f m = f t n t N f t =0.005 in. tooth rev = 1,910 rpm N = CS 12 in. dd ft = tooth rev f m = 0.005 in. 2 teeth 1,910 rpm min 250 ft 12 in. 0.5 in. ft min rev Calculate the feed rate for end milling aluminum with a 2 flute, inch HSS end mill. Example Feed Rate
  • Slide 20
  • See teacher for solution Your Turn Calculate the feed rate for face milling aluminum with a 4 flute, inch HSS end mill.
  • Slide 21
  • Power of spindle motor Condition of cutting tool Depth of cut Quality of surface finish required Roughing vs. finish cuts Condition of the machine Strength of fixture Factors That Affect Feed Rates
  • Slide 22
  • Feed rate at which mill can plunge into material Plunge Feed Rate pfr = f m 2 pfr = Plunge feed rate in. f m = Feed rate in. min f m = f t n t N pfr = f t n t N 2
  • Slide 23
  • = 687 rpm f m = f t n t N pfr = f t n t N pfr = f m 2 2 n t = 4 teeth f t = 0.002 in. tooth rev N = CS 12 in. dd ft = tooth rev pfr = 0.002 in. 4 teeth 687 rpm 2 pfr = 2.7 in. min 90 ft 12 in. 0.5 in. ft min rev Calculate the plunge feed rate for plunging into mild steel with a 4 flute, inch HSS end mill. Reference charts on next slides Example Plunge Feed Rate
  • Slide 24
  • Milling Speeds for High Speed Steel Tools MaterialCutting Speed in Surface ft/min Magnesium300 Aluminum250 Brass and Bronze150 Copper100 Cast Iron (Soft)80 Cast Iron (Hard)50 Mild Steel90 Cast Steel80 Alloy Steel (Hard)40 Tool Steel50 Stainless Steel60 Titanium50 High Manganese Steel30 Note: Double Speed for Carbide Cutting Tools Recommended Cutting Speeds
  • Slide 25
  • Tool Feed (in./tooth/rev) MaterialFace MillSide MillEnd Mill Magnesium.005-.020.004-.010.005-.010 Aluminum.005-.020.004-.010.005-.010 Brass and Bronze.004-.020.004-.010.005-.010 Copper.004-.010.004-.007.004-.008 Cast Iron (Soft).004-.016.004-.009.004-.008 Cast Iron (Hard).004-.010.002-.006 Mild Steel.004-.010.002-.007.002-.010 Alloy Steel (Hard).004-.010.002-.007.002-.006 Tool Steel.004-.008.002-.006 Stainless Steel.004-.008.002-.006 Titanium.004-.008.002-.006 High Manganese Steel.004-.008.002-.006 Note: Double Speed for Carbide Cutting Tools Recommended Tool Feed
  • Slide 26
  • Now Your Turn See teacher for solution Calculate the plunge feed rate for plunging copper with a 4 flute, inch HSS end mill.
  • Slide 27
  • Other special operations require slower speeds: Reaming to of that used for drilling the material Counterboring of that used for drilling the material Countersinking of that used for drilling the material Tapping (threading) Determined by many factors (usually range from 50 to 300 rpm) CS 12 in./ft dd N =N = Special Operations
  • Slide 28
  • Black, J., Kohser R.(2008). DeGarmos materials and processes in manufacturing (10 th ed.). Danvers, MA: John Wiley & Sons, Inc. Kibbe, R.R., Neely, J.E., Meyer, R.O., & White, W.T. (2002). Machine tool practices. Upper Saddle River, NJ: Prentice Hall. Oberg, E., Jones F. D., Horton, H. L., & Ryffell, H. H. (2000). Machinerys handbook (26 th ed.). New York, NY: Industrial Press Inc. References