Thermal Expansion Calculation

7/30/2019 Thermal Expansion Calculation

1/24

Diameter

0.0625

Radius

Elev from

Top

Rad-Elev

from top Width

2x(1/2

Widths)

0.0313 0.0150 0.0163

Rad^2 ^2 K15-M15 SqrtM15 O15*2

0.0010 0.0003 0.0007 0.0267 0.0534

Diameter

Elev from

TopWidth of

Line

Height of

Letter (X8)

0.0625 0.0050 0.0339 0.2712

0.0625 0.0100 0.0458 0.3664

0.0625 0.0150 0.0534 0.4272

0.0938 0.0150 0.0688 0.5504

0.0938 0.0200 0.0768 0.6144

0.0938 0.0250 0.0829 0.66320.0938 0.0300 0.0875 0.7000

0.1250 0.0200 0.0917 0.7336

0.1250 0.0300 0.1068 0.8544

0.1250 0.0400 0.1166 0.9328

0.1250 0.0500 0.1225 0.9800

Ball End Mill Elevation down to Width of line


2/24

Enter

Degree

Enter

Minute

Enter

Second

Dedgee in

Decimal

Distance across in Inches

at 100 feet

Distance across in

Inches at 1 ft

1.000 30.000 1.000 1.50028 32.149 0.3215

45.000 29.000 45.48333 974.643 9.7464

2.000 0.00056 0.012 0.0001

4.000 0.00111 0.024 0.0002

10.000 0.00278 0.060 0.000685.000 0.02361 0.506 0.0051

1.000 0.01667 0.357 0.0036

1.000 1.00000 21.429 0.2143

1.000 0.00028 0.006 0.0001

10.000 0.00278 0.060 0.0006

100.000 0.02778 0.595 0.0060

1000.000 0.27778 5.952 0.0595

Find Sec

Find Degree

in Decimal Find Dist per ft

16.667 0.005 0.0010

33.333 0.010 0.0020

83.333 0.024 0.0050

333.333 0.095 0.0200


3/24

Distance across in

Inches at 10"

Distance across in

Inches at 1"

Distance

across at 60"

0.2679 0.02679 1.6074

8.1220 0.81220 48.7321

0.0001 0.00001 0.0006

0.0002 0.00002 0.0012

0.0005 0.00005 0.00300.0042 0.00042 0.0253

0.0030 0.00030 0.0179

0.1786 0.01786 1.0714

0.0000 0.00000 0.0003

0.0005 0.00005 0.0030

0.0050 0.00050 0.0298

0.0496 0.00496 0.2976

Enter Dist per 5ft

0.0050

0.0100

0.0250

0.1000


4/24

Enter

Diameter Radius EnterX axis

(Azimuth)

Radius=

(Hypoten

use)

Sine=Az

imuth/Hy

p

0.0310 0.0155 0.0080 0.0155 0.5161

Radi


5/24


6/24

Calculated

AngleDegrees

from Top

Hyp *

Hyp

Opp *

Opp

Adj =

SqRt of

H*H+O*O

Calculate

d

Elevation

from Top(Radius-Adj)

31.0730 0.0002 0.0001 0.0133 0.0022

x= 0.0080

y= 0.0133

R= 0.0155

us


7/24


8/24

Calculated

Y=Radius-Elev

from Top

Width of

2X

Azimuth

0.0133 0.0160


9/24

SS 0.29

Steel 0.25

Aluminum 0.1

Length Width Height Pounds per Cubic Inch Weight Of Piece in Lbs

12 12 12 0.25 432

48 48 0.375 0.1 86.4

12 12 1 0.1 14.4

12 12 0.25 0.1 3.6

0

0

0

0

0

00

0

Metal Weight Calculator


10/24

SpeedAndFeed40

(Alum 160HSS

500Carb) (Steel

80HSS

250Carb)

(SS303 60HSS

180Carb)

(SS304 40HSS100Carb)

(Aluminum=3.0)

(Alum Alloy=1.5)

(HR Steel=0.8)(SS 304=0.35)

= .

(Minimum

Oil=0.7)

(Mist=0.8)

(Flood=1.0)

(LOWER IF

CHIPS

STICKING TOFLUTES)

(Regular=1) (Long=2)

(ExLong=4) (Reduced

Shank=2) (Quick

Switch Adapter to

Collet Holder=2)

(Roughing EM lowerNumber -1 )

Enter

SFPM

(effects

Hp

needs)

Enter

diameter

of end

mill

(effects

Hp

needs)

Enter

flutes

on end

mill

(effects

FEED &

Hp

needs)

Enter (MR)

Machinabilty

Rating of

Material

cutting

(effects DOC

and FEED )

Type of

Milling End

Milling=1.0

Side

Milling=1.2

Side millingcools End

Mill better

so RPM

faster

Enter

Coolant?

(Effects

RPM and

FEED)

Enter Cutter

Length Factor

(effects Depth

Of Cut )

500 0.5000 4 1.50 0.7 2.0350 0.5000 4 1.50 End Milling 0.7 2.0

420 0.5000 4 1.50 Side Milling 0.7 2.0

.1) This Excel sheet calculates Maximum Safe End Mill Depth of Cut, RPM, Feed, and Horsepower requirements ( and Cubic I

cut and End mill diameter, length and number of flutes.

.2)Use at your own risk and check all recommendations it makes with your own calculations.

.3)Recommend using Feed over ride at less than 30% and slowly increasing if everything looks OK. Feed is the main throttle c

.4) These are Maximum recommendations and your Vise / Fixture may not be able to hold part and or it may bend under cuttin

Depth of Cut Divider and or Material Ratings and or Cutter Length Factor AND OR COOLANT depending on your experiences.

smaller diameters), this jamming flutes full of chips can destroy an end mill quickly.

Page 10


11/24

SpeedAndFeed40

Normal Range(0.003 0.010)

Normal FEED

Adjustment Factor

Range FOR CHIP

CLEARANCE (1.0 3.0) (DEEP SLOT=3)

Enter Depth of

Cut Divider

(effects Depth

of Cut)

(Normal =3-5)

Enter

Main Chip

thickness

((dia*

H3*D3)+

0.0005)),

effects

Feed,

Cubic

IPM, HP

ACTUAL CHIP

THICKNESS

adjusted (fordiameter of

end mill and

high flute

number)

Hp needs

= Cubic

IPM / MR(Bridgepo

rt


12/24

SpeedAndFeed40

4.0

Depth Of

Cut is Dia x

MR / (LF x

Depth

Divider) Stepover

0.094 0.500

1.000 0.047

0.250 0.188End Milling

Depth METRIC

MM

2.38125

Page 12


13/24

DECIMAL

EQUIV

DRILL

SIZE MM TAP SIZES

DECIMAL

EQUIV

DRILL

SIZE MM

0.0135 80 0.3429 0.1181 3.0000

0.0145 79 0.3683 0.1200 31 3.0480

0.0156 1/64 0.3962 0.1250 1/8 3.1750

0.0157 0.4000 0.1285 30 3.26390.0160 78 0.4064 0.1299 3.3000

0.0180 77 0.4572 0.1360 29 3.4544

0.0197 0.5000 0.1405 28 3.5687

0.0200 76 0.5080 0.1406 9/64 3.5712

0.0210 75 0.5334 0.1440 27 3.6576

0.0225 74 0.5715 0.1457 3.7000

0.0236 0.6000 0.1470 26 3.7338

0.0240 73 0.6096 0.1495 25 3.7973

0.0250 72 0.6350 0.1520 24 3.86080.0260 71 0.6604 0.1540 23 3.9116

0.0276 0.7000 0.1562 5/32 3.9675

0.0280 70 0.7112 0.1570 22 3.9878

0.0292 69 0.7417 0.1575 4.0000

0.0295 0.7500 M1 X 0.25 0.1590 21 4.0386

0.0310 68 0.7874 0.1610 20 4.0894

0.0313 1/32 0.7938 0.1654 4.2000

0.0315 0.8000 0.1660 19 4.2164

0.0320 67 0.8128 0.1695 18 4.30530.0330 66 0.8382 0.1719 11/64 4.3663

0.0335 0.8500 M1.1 X 0.25 0.1730 17 4.3942

0.0350 65 0.8890 0.1770 16 4.4958

0.0354 0.9000 0.1800 15 4.5720

0.0360 64 0.9144 0.1820 14 4.6228

0.0370 63 0.9398 0.1850 13 4.6990

0.0374 0.9500 M1.2 X 0.25 0.1875 3/16 4.7625

0.0380 62 0.9652 0.1890 12 4.8006

0.0390 61 0.9906 0.1910 11 4.8514

0.0394 1.0000 0.1935 10 4.9149

0.0400 60 1.0160 0.1960 9 4.9784

0.0410 59 1.0414 0.1969 5.0000

0.0420 58 1.0668 0.1990 8 5.0546

0.0430 57 1.0922 0.2010 7 5.1054

0.0433 1.1000 M1.4 X 0.3 0.2031 13/64 5.1587


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0.0465 56 1.1811 0.2040 6 5.1816

0.0469 3/64 1.1913 #0-80 0.2055 5 5.2197

0.0492 1.2500 M1.6 X 0.35 0.2090 4 5.3086

0.0520 55 1.3208 0.2130 3 5.4102

0.0550 54 1.3970 0.2188 7/32 5.5575

0.0595 53 1.5113 #1-64, #-72 0.2210 2 5.61340.0625 1/16 1.5875 0.2280 1 5.7912

0.0630 1.6000 M2 X 0.4 0.2340 A 5.9436

0.0635 52 1.6129 0.2344 15/64 5.9538

0.0670 51 1.7018 0.2362 6.0000

0.0689 1.7500 M2.2 X 0.45 0.2380 B 6.0452

0.0700 50 1.7780 #2-56, #2-64 0.2420 C 6.1468

0.0730 49 1.8542 0.2460 D 6.2484

0.0760 48 1.9304 0.2500 1/4&E 6.3500

0.0781 5/64 1.9837 0.2570 F 6.52780.0785 47 1.9939 #3-48 0.2610 G 6.6294

0.0787 2.0000 0.2656 17/64 6.7462

0.0807 2.0500 M2 X 0.045 0.2660 H 6.7564

0.0810 46 2.0574 0.2677 6.7996

0.0820 45 2.0828 #3-56 0.2720 I 6.9088

0.0860 44 2.1844 0.2756 7.0000

0.0890 43 2.2606 #4-40 0.2770 J 7.0358

0.0935 42 2.3749 #4-48 0.2810 K 7.1374

0.0938 3/32 2.3825 0.2812 9/32 7.1425

0.0960 41 2.4384 0.2900 L 7.3660

0.0980 40 2.4892 0.2950 M 7.4930

0.0984 2.5000 M3 X 1.5 0.2969 19/64 7.5413

0.0995 39 2.5273 0.3020 N 7.6708

0.1015 38 2.5781 #5-40 0.3071 7.8000

0.1040 37 2.6416 #5-44 0.3125 5/16 7.9375

0.1065 36 2.7051 #6-32 0.3150 8.0000

0.1094 7/64 2.7788 0.3160 O 8.0264

0.1100 35 2.7940 0.3230 P 8.2042

0.1110 34 2.8194 0.3281 21/64 8.3337

0.1130 33 2.8702 #6-40 0.3320 Q 8.4328

0.1142 2.9000 M3.5 x 0.6 0.3346 8.5000

0.1160 32 2.9464 0.3390 R 8.6106


15/24

TAP SIZES

DECIMAL

EQUIV

DRILL

SIZE MM

0.3438 11/32 8.7325

0.3480 S 8.8392

0.3543 9.0000

0.3580 T 9.0932M4 x 0.7 0.3594 23/64 9.1288

#8-32, #8-36 0.3680 U 9.3472

0.3750 3/8 9.5250

0.3770 V 9.5758

0.3860 W 9.8044

M4.5 x 0.75 0.3906 25/64 9.9212

0.3937 10.0000

#10-24 0.3970 X 10.0838

0.4016 10.20000.4040 Y 10.2616

0.4062 13/32 10.3175

0.4130 Z 10.4902

0.4219 27/64 10.7163

#10-32 0.4331 11.0000

0.4375 7/16 11.1125

M5 x 0.8 0.4531 29/64 11.5087

0.4688 15/32 11.9075

0.4724 12.00000.4844 31/64 12.3038

0.5000 1/2 12.7000

#12-24 0.5118 13.0000

0.5156 33/64 13.0962

#12-28 0.5312 17/32 13.4925

#12-32

0.5469 35/64 13.8913

0.5512 14.0000

0.5625 9/16 14.2875

0.5781 37/64 14.6837

0.5906 15.0000

M6 x 1.0 0.5938 19/32 15.0825

0.6094 39/64 15.4788

1/4-20 0.6102 15.5000

0.6250 5/8 15.8750


16/24

0.6299 16.0000

0.6406 41/64 16.2712

0.6562 21/32 16.6675

1/4-28, 1/4-32 0.6693 17.0000

0.6719 43/64 17.06630.6875 11/16 17.4625

0.6890 17.5000

0.7031 45/64 17.8587

M7 x 1.0 0.7087 18.0000

0.7188 23/32 18.2575

0.7344 47/64 18.6538

0.7480 19.0000

0.7500 3/4 19.0500

5/16-18 0.7656 49/64 19.44620.7677 19.5000

5/16-20 0.7812 25/32 19.8425

0.7874 20.0000

M8 x 1.25 0.7969 51/64 20.2413

5/16-24 0.8125 13/16 20.6375

0.8268 21.0000

5/16-28 0.8281 53/64 21.0337

0.8438 27/32 21.4325

0.8594 55/64 21.8288

0.8661 22.0000

0.8750 7/8 22.2250

0.8906 57/64 22.6212

0.9055 23.0000

M9 x 1.25 0.9062 29/32 23.0175

3/8-16 0.9219 59/64 23.4163

0.9375 15/16 23.8125

0.9449 24.0000

0.9531 61/64 24.2087

3/8-20 0.9688 31/32 24.6075

0.9843 25.0000

M10 x 1.5 0.9844 63/64 25.0038

3/8-24 1.0000 1 25.4000


17/24

TAP SIZES

3/8-28, 3/8-32

7/16-14

7/16-16

7/16-20

M12 x 1.757/16-28

7/16-32

1/2-13

1/2-16

1/2-20

1/2-28, 1/2-32

M14 x 2.09/16-12

9/16-16

9/16-18, 9/16-20

9/16-24, 9/16-28

9/16-32, 5/8-11

5/8-12

M16 x 2.0

5/8-16

5/8-18, 5/8-20

5/8-24, 5/8-28, 5/8-32

11/16-12

M18 x 2.5

11/16-16


18/24

11/16-20

11/16-24, 11/16-28

11/16-32, 3/4-10

3/4-123/4-16

M20 x 2.5

3/4-20

3/4-28, 3/4-32

13/16-12

13/16-16

13/16-20, 7/8-9M22 x 2.5

13/16-32

7/8-12

7/8-14, 7/8-16

M24 x 3.0

7/8-20

7/8-28, 7/8-32

15/16-12

15/16-16, 1.0-8

15/16-20

15/16-28, 15/16-32

1.0-12

1.0-16, 1-1/16-8

M27 x 3.0

1.0-20

1.0-28, 1.0-32

1-1/16-12, 1-1/8-7

1-1/16-16, 1-1/8-8


19/24

Material Type

Coefficent of

Expansion Inch

per F

Enter

Length

Enter

Temperature

difference in F

Length

change

6.000 30.0ABS 0.0000410 6.000 30.0 0.007

ABS, Glass Fiber Reinforced 0.0000170 6.000 30.0 0.003

Acetal / Delrin 0.0000590 6.000 30.0 0.011

Acetal, Glass Fiber Reinforced 0.0000220 6.000 30.0 0.004

Aluminum 0.0000130 6.000 30.0 0.002

Acrylic Sheet Cast 0.0001300 6.000 30.0 0.023

Acrylic Extruded 0.0000450 6.000 30.0 0.008

Brass 0.0000104 6.000 30.0 0.002

Cellulose Acetate 0.0000722 6.000 30.0 0.013

Cement 0.0000060 6.000 30.0 0.001

Concrete 0.0000080 6.000 30.0 0.001

Concrete Structure 0.0000055 6.000 30.0 0.001

Copper 0.0000093 6.000 30.0 0.002

Epoxy Unfilled Casting 0.0000310 6.000 30.0 0.006

Glass Plate 0.0000050 6.000 30.0 0.001Glass Pyrex 0.0000022 6.000 30.0 0.000

Invar 0.0000008 6.000 30.0 0.000

Nylon Type 6 0.0000472 6.000 30.0 0.008

Phenolic Resin without Fillers 0.0000444 6.000 30.0 0.008

Polycarbonate Unfilled 0.0000390 6.000 30.0 0.007

Polyethylene 0.0001110 6.000 30.0 0.020

UHMWPE 0.0000600 6.000 30.0 0.011

PVC 0.0000280 6.000 30.0 0.005

Silver 0.0000107 6.000 30.0 0.002

Stainless 304 0.0000096 6.000 30.0 0.002

Stainless 316 0.0000089 6.000 30.0 0.002

Steel 0.0000060 6.000 30.0 0.001

Wood Pine 0.0000028 6.000 30.0 0.001

Zinc 0.0000165 6.000 30.0 0.003


20/24

Thread Depth

Number of

Threads Factor

Double Depth

(Lathe Cross

slide)

Double Depth using

Compound at 30

degree

ompoun a

30 degree

direct reading

Flat on Cutter

Tip

1.30003.5 1.3000 0.371 0.4289 0.2144 0.0357

4.0 1.3000 0.325 0.3753 0.1876 0.0313

4.5 1.3000 0.289 0.3336 0.1668 0.0278

5 1.3000 0.260 0.3002 0.1501 0.0250

6 1.3000 0.217 0.2502 0.1251 0.0208

7 1.3000 0.186 0.2144 0.1072 0.0179

8 1.3000 0.163 0.1876 0.0938 0.0156

9 1.3000 0.144 0.1668 0.0834 0.0139

10 1.3000 0.130 0.1501 0.0751 0.0125

11 1.3000 0.118 0.1365 0.0682 0.0114

12 1.3000 0.108 0.1251 0.0625 0.0104

13 1.3000 0.100 0.1155 0.0577 0.0096

14 1.3000 0.093 0.1072 0.0536 0.0089

16 1.3000 0.081 0.0938 0.0469 0.0078

18 1.3000 0.072 0.0834 0.0417 0.0069

20 1.3000 0.065 0.0751 0.0375 0.0063

24 1.3000 0.054 0.0625 0.0313 0.0052

28 1.3000 0.046 0.0536 0.0268 0.0045

32 1.3000 0.041 0.0469 0.0235 0.0039

40 1.3000 0.033 0.0375 0.0188 0.0031

1.3000 #DIV/0!

Double Depth of American National Thread

Page 20


21/24

Xsq + Ysq=Rsq

Xsq= Rsq Ysq

Enter Diameter= 10.0000 Enter Diameter= 10.0000 Enter X= 2.0000

Rad= 5.0000 Rad= 5.0000 Xsq= 4.0000

Enter Y= 3.0000 Enter X= 3.0000 Enter Y= 2.0000

XSQ= 16.0000 Ysq= 16.0000 Ysq= 4.0000

Then X= 4.0000 Then Y= 4.0000 Radius(Hyp)sq= 8.0000

Radius (Hyp) = 2.8284

X Y X Y

4.0000 3.0000 3.0000 4.0000

X,Y Coordinates X,Y Coordinates

Xsq+Yysq=Rad(Hyp)sq

X and Y cannot be

bigger than Radius

If one corner of

triangle is X0,Y0

T0 FIND MISSING X ENTER

Diameter AND Y

T0 FIND MISSING Y ENTER

X

know X and Y of other

corner


22/24


23/24

Sine =Opp/Hyp

Cosine= Adj/Hyp

Enter

DegreesGives

Number

Enter

NumberGives

Degrees

Tangent =Opp/Adj Sine 30.0000 0.5000 ArcSin 0.5000 30.0000

Cosine 30.0000 0.8660 ArcCos 0.8660 30.0029

Tangent 45.0000 1.0000 ArcTan 1.0000 45.0000

Enter Opp (Leave

Blank if not sure) 12.0000

Enter Adj (Leave

Balnk If not sure) 12.0000

Enter Hyp (LeaveBlank if not sure)

Enter Angle 45.0000Sine Cosine Tangent Opp Adj Hyp

45.0000 45.0000 45.0000 12.0000 12.0000 0.0000

0.7071 0.7071 1.0000

Opp=Sine * Hyp 0.0000

Hyp= Opp/Sine 16.9706

Adj = Cosine * Hyp 0.0000Hyp = Adj/Cosine 16.9706

Opp = Tan * Adj 12.0000Adj = Opp/Tan 12.0000

Enter

degrees

Degrees

180Indexing Table 1.0000 -179.0000

2.0000 -178.0000

3.0000 -177.0000

4.0000 -176.0000

5.0000 -175.0000

6.0000 -174.0000

-180.0000

-180.0000


24/24

-180.0000

-180.0000

Documents

Thermal Expansion Calculation