TABLE OF CONTENTS MACHINING OPERATIONS CUTTING SPEEDS AND FEEDS



                 

       

ESTIMATING SPEEDS AND MACHINING POWER

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SPEED AND FEED TABLES

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MICROMACHINING
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TABLE OF CONTENTS MACHINING OPERATIONS MACHINING ECONOMETRICS

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SCREW MACHINES, BAND SAWS, CUTTING FLUIDS

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MACHINING NONFERROUS METALS AND NON-METALLIC MATERIALS

  
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SCREW MACHINES, BAND SAWS, CUTTING FLUIDS

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GRINDING FEEDS AND SPEEDS

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TABLE OF CONTENTS MACHINING OPERATIONS GRINDING AND OTHER ABRASIVE PROCESSES

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GRINDING AND OTHER ABRASIVE PROCESSES

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TABLE OF CONTENTS MACHINING OPERATIONS GRINDING AND OTHER ABRASIVE PROCESSES

(Continued)
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CNC NUMERICAL CONTROL PROGRAMMING

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CUTTING SPEEDS AND FEEDS

Introduction to Speeds and Feeds Work Materials.
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Table 1. (Continued) Tool Troubleshooting Check List

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(Continued)

Cutting Speed Formulas


      
   
  
   
    

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Revolutions per Minute for Various Cutting Speeds and Diameters (Metric Units)

SPEED AND FEED TABLES

How to Use the Feeds and Speeds Tables Introduction to the Feed and Speed Tables.
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c a

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Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

s Opt.

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Opt.

Avg.

c ` ^ c

\ ^ ^ _ ^ ^ Y

\ ^

W f

Opt.

Z _

c _

\ _

\ _ Y

Z a

Z ^ Y

c _ a

\ _ _ _

\ _ _

c a

h Z

` \ _ Y

` a

[ _ Y Y

R N

R W

Table 1. (Continued) Cutting Feeds and Speeds for Turning Plain Carbon and Alloy Steels

Avg.

Z [ _ _

c c [

` ^ ` ^ a c [

x N

Metric Units: f Opt. Avg. Opt.

Z b _ _ Z

` a a

c _

` \ ^ \ ^ Y Y Y a

Table 5c

Z _ _

` ^ ^

` ^

` ^

` ^

W y

Z _

Z _ _

Z a a

Z a a a a

o M

Avg.

Z _ _

N t

Z [ _

V n

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a _ Y

^ Y

x N

Opt.

Z _

Z _

Machinery's Handbook 29th Edition

[ ^ Y ^

[ ^ Y _ Y _

U |

Z _

Z _

\ _

\ _

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R W

Opt.

Z _ _

W Y

` _

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Table 5b

Avg.

Z _ _ _ _

Table 16

Avg.

c a

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Opt.

Z _

Z _

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p N

q r

W q

q ` N

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Table 5a

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h Y

[ b

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n ~

n R W

V d

R N _ R p T

R N

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

s Opt.

Avg.

Avg.

Avg.

Metric Units: f Opt. Avg. Opt.

Table 5c

Table 2. Cutting Feeds and Speeds for Turning Tool Steels

Opt.

Machinery's Handbook 29th Edition

Table 5b

Avg.

Table 16

Avg.

Opt.

f Avg.

Opt.

f s

f s

f s

f s

f s

f s

f s

f s

Table 5a

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Opt.

Avg.

Opt.

Avg.

Z _ _ _ _ _ _

\ ^

b ^ ^

b ^ ^

W f

Opt.

Z _ _

Z _

Z b ^ ^

` [

Z _ _ _

Z _ _

` ^ Y ^ Y ^ Y ^

` ^ Y ^ Y ^ ^ Y

a Y Y

a Y

R W

Opt.

Z _ _

Z _

Z _

c a a

c a ^ a a

~ _

Metric Units: f

Avg.

Table 3. Cutting Feeds and Speeds for Turning Stainless Steels

Opt.

\ _

\ _

Avg.

\ ^

c \ ^ \

\ _

^ Y Y

^ Y Y Y

^ Y

^ Y Y Y Y Y

W k

U y |

Machinery's Handbook 29th Edition

Opt.

` _

` _ Y

` _ Y

o O

R W

t N

Avg.

Table 16

Q T

Z ~

z P

Opt.

Z _

Z a ^

[ ^

[ ^ Y

Z a ^

[ ^ Y ^

[ ^

c _ Y Y _ Y

c _ Y Y

[ _ Y Y Y

f s

f s

f s

f s f s

f s

f s

f s

f s

` Z _ _ _ _ _ _ _ Z Z Z Z _

s W N

Z a Y

` ^

` a _ ^ ^ _

W x _ Q T d _ d

Y |

c | _

z P

Z _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Z _ _

c a

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[ ^

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[ ^

[ ^ ^

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Z _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d _ d d _ d _ d _ d

R R

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Table 1

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Y k O P k k V N

W j s

R W c

^ Y

R W V L

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg.

Avg.

Z ^

` [

^ Y

[ Y

Opt.

c c c _

Z _

a V

c _ c c c ^

W f

^ R

Z _ _

b ^

a a a [

W R

Avg.

a _

a Y

` Y Y

k }

Opt.

~ _

Z a _ Y

[ _ Y Y _

c a _

c ^ Y

Metric Units: f

Table 4a. Cutting Feeds and Speeds for Turning Ferrous Cast Metals

Table 5c

R N

Avg.

b _ Y

c a _ ^

` a a

Opt.

c _ Y

c _

Z _

\ Y

Avg.

Z _ _ _

c ^ ^ a ^

\ ^

^ Y

b _ _ Y Y

[ _ Y Y

Opt.

Table 5b

W S

Z _

Machinery's Handbook 29th Edition

` a a a a a

` a

c a

U |

[ _

[ ^

[ ^

Avg.

Z ^ ^

c ^ ^ ^

b _

Y W R

Opt.

Z _

Z _

` a a

Z a ^ a ^

W M

[ ^

N Z ~

j N

W M

Avg.

R N Z _ _ _ Z Z

O W

` ^ ^

c ^

\ ^

Z a ^ ^

[ ^ Y Y Y Y Y

Y Y Y

k n {

Opt.

Z _

y V W

c a a ` a a a a

[ a

[ Y

Q T

f s

f s

f s

f s

f s

f s

Table 16

Z _

Z _

Z _ _

s W

` ^

` \ _ b ^ \ \

` _ ^

W x

Y |

s |

Z _ _

Z _

Z _ ` _ a [

c _

[ ^

[ ^

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O P Z d d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

Z d

R R

[ _

[ _ Y

c _

x N

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V ^

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W R n

N a

W R Y Z Z O

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Z _

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[ ^

Z X X X X

Z U U U U U

Table 5a

X _

i i i

| M N M N M N N N

| o

y y y o Q U U U U

Q O _ ]

O { p { p { p { p { p p p p

Z O

V O

s c

W e L W

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Opt.

Avg.

Avg.

Z _ _

c a

c ^ Y

\ ^

W f

Opt.

Z _ _ _

[ _

a ^ Y

c _ ^

` a _ Y Y

` a

Opt.

` _ Z _

c _

Z _ _

b _ Y

R N

Z Z Z Z

R W

Avg.

Z _ _

c _

b _ Y Y

` a

b _

` a a

Opt.

Z b _ _

\ _

Z _

Z _

c _ ^ _

a Y

Table 4b. Cutting Feeds and Speeds for Turning Ferrous Cast Metals

Metric Units: f

Avg.

Z _ _ _

Z _

` ^ ^

` ^

\ ^

\ ^

b ^

` _ ^ Y

W y

Opt.

Z _ _ _

Z _

c ^ a a a

c [ ^ Y [

c [

[ ^

V W

N n

Avg.

Z _ _

W O P

Z ^ ^ Y Y Y

\ _ Y Y

V y

T l R

Opt.

Z _

b a _

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Machinery's Handbook 29th Edition

c [ ^ Y

` _ Y Y _

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Z _ _

Z _ _

[ ^ ^ Y ^ _

\ _ ^

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[ ^

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Z _

W M M

Z a a a

Z ^

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` _

Z a a

Y V

c ^

[ ^ Y ^ Y

j U

n R

Avg.

Z _

Y M N

c { a a

c a

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Opt.

^ Y

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f s

f s

f s

f s

f s

f s

f s

f s

s |

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Table 16 Table 4a

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Z _ _

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Z d _ d

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Z d

Z d

Z d _ d _ d _ d

Z d

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Z d _ d _ d

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W c

W [ c a

W e e W L W T

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg.

c _ \

Z a

fl

~ Z ~

U O

Vopt

Table 5b. Tool Life Factors for Turning with Carbides, Ceramics, Cermets, CBN, and Polycrystalline Diamond

R N

n P

x N

W Q

Z a

W O

V Vopt Ff Fd

R V

Table 5a. Turning-Speed Adjustment Factors for Feed, Depth of Cut, and Lead Angle

R P

Z a a

` _

g P

\ _

fl

~ Z ~ Z ~ Z ~

^ n P

x N

Fd

W Q

Machinery's Handbook 29th Edition

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` \ _

fm

R N

W O

h V

R P

Z a

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R P

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fm V

fopt

fopt fopt VT fl V

Fd

fs

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Tables 1

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fopt

g P

^ Y Y

Ff

Z a

W Q

W O h

R P

` a Y

Z a

Tables 1

optimum

O k

Z _ _

optimum

Optimum

Copyright 2012, Industrial Press Inc., New York, NY

Vavg Vopt

fm

fs

VT

fs V

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optimum

Ff

fm

fopt

Table 5c. Cutting-Speed Adjustment Factors for Turning with HSS Tools
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Tables 1
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Example 3, Turning:
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Table 5a
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Example 3
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Example 3
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Table 5b
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Tool Life
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Cutting Speed V V V V V V V
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Table 6. Cutting Feeds and Speeds for Turning Copper Alloys

Group 1
 / !   /   & $ 3   '   & 4 !  + ! 4 !  & %  % 3  &      +  ' + 3  &       4 /   ' + 0 !   0 !   3   '      4 /   ' + 3  &       4 /   ' +  ' *  & $

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Group 2
$  *  '  * 3  &   &    '  / & $ &    % +  3  &   "  + ! 4   $  /  ' 3   '  2 2 2 % *   & $ ( 3  &    ' !  3   %    $  ( 3   ' 

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Group 3
$  *  '  * 3   '    ( $ $   * /  0 0    * *   /  & $ 4 2 2 2 3   '   0 0   '  /  $  0 0   '  /  $ $  /   $ (  /

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f Metric Units: f
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Table 16

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Table 7

Table 7. Cutting Feeds and Speeds for Turning Titanium and Titanium Alloys

f Metric Units: f

Opt.

Avg.

f s f s f s

f s

f s
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Table 15a
  %  ) , !   )   %  & ' % %  0 !  ) /  

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Table 5c
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Table 5b
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Table 5a
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Table 16

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Table 8. Cutting Feeds and Speeds for Turning Light Metals

f Metric: f

s s

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f s

f s

f s f s

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Table 16

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Table 9. Cutting Feeds and Speeds for Turning Superalloys

f Metric Units: f

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Avg.

Opt.

Avg.

Opt.

Avg.

Opt.

Avg.

f s f s

f s

f s

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Speed and Feed Tables for Milling. Tables 10

S 9 : H H : ; ? N < 6 B L 7 L : ; 7 < 6 C : 8 @ 7 @ A 6 6 B = D H > 9 ; = L ; U 6 > @ C 6 6 B @ ? : R 6 ; : ;

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Tables 10
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Tables 15b 15c

M M > @ : ; ? 7 < 6 C L = 7 D 8 @ :

15d Table 15e Table 16

S B N D D H H N H 6 B L 7 L C D 8 6 ; B 9 : H H : ; ? E N F : ; = < M L ; L \ : L H B 6 A

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>

>

End Milling:
T : 7 < L B : L 9 6 7 6 8 : ; = < [ C > H H @ H D 7 ] N

<

<

<

>

<

<

>

Table 15b
@ A 6 6 B @ : C 7 < 6 L 9 6 7 6 8 @ N

>

<

<

>

Table 15c
R L H : B C D 8 L H

>

<

>

<

<

Face Milling:
9 : H H M D A 6 8 L 7 : ; ? T : ; = < M L ; B 8 L B : L H B

<

<

<

<

>

<

>

<

<

>

<

<

>

>

i A : D 7

<

<

>

<

<

<

>

Table 15d
= = 6 ; 7 8 : = : 7 X [ L 9 6 7 6 8 D 8 9 D

>

<

<

>

<

<

>

<

<

>

>

<

>

Tables 15b
7 L C D 8 @ H : 7 9 : F N O : ; = < M B : L

15c
] ; ? L 8 6 6 7 6 8

<

Slit and Slot Milling:

L ; ? H 6 7 D D H T : 7 < L = > 7 7 6 8 : ; = < N A 6 6 B @ L 8 6 R L H : B C

<

<

<

D
: B 7 B 6

<

<

>

<

<

<

>

<

<

<

>

>

>

>

>

Table 15e
8 9 : H H : ; ? =

>

>

Using the Feed and Speed Tables for Milling: f

6 B A 6 8 7 D D 7 < [ ] M T < : = < : @ 6 \ A 8 6 @ @ 6 B : ; : ; = < 6 @ : B 6 8 : ; @ 6 H 6 = 7 : ; ? 7 < 6 C 6 6 B A 6 8 7 D D 7 < L ; B ; D C D 8 9 9 D ; ? 7 < 6 C L = 7 D 8 @ 7 D = D ; @ : B 6 8 L 8 6 7 < 6 = > 7 7 : ; ? 7 D D

<

>

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<

<

<

fm
T < 6 8 6

ft nt N
: ; : ; = < 6 @ A 6 8 9 : ; > 7 6 [ : A 9 ]

fm = ft = nt = N=

<

<

<

>

<

<

>

<

<

>

>

Example:
W K D C E F < ; W T : 7 < 7 6 6 7 <

>

<

<

<

<

>

<

<

<

>

<

<

<

>

<

<

<

>

<

<

>

Table 11

Table 15a
M

<

<

<

N
Z

V D
J P P P P P P P P

P P P P P P P P P P E O W

fm Example 1, Face Milling:

C L = 6 9 : H H : ; ? L ; L H > 9 : ; > 9 B = > 7 7 6 8 M L ^ P : ; = < T : B 7 < D C = > 7 M

ft nt N
I : A 9

: 9 L 7 6 H X

<

>

<

>

<

<

<

>

<

<

Table 10
C D 8 C L = 6 9 : H : ; N Q 7 D D 7 < C 6 6

<

>

>

<

<

6 @ V

D C 6 =

<

<

<

>

<

<

>

D
M 7 < 6 T H X M 7

<

<

<

>

ar
M L @ @ < @ 6 B T

<

<

>

Fig. 3
7 L B _ > @ 7 9 L 8 L B : L H

<

<

>

<

>

>

<

>

<

>

>

ar D
Q ] 6 ` > : 8 6 ; B : 7 : D ;

i 8 <

i ` B

<

>

<

ar D
Q _ > @ 7 6 B = 7 < 6 7 T

>

i H = 6

<

>

>

>

<

>

V
6 ; : 7 M L ;

>

<

V Vopt Ff Fd Far Ff Fd Far

M Z L ; B M M L ; B L 8 6 > 7 M 8 6 @ A 6 = 7 : R 6 H X M D U 7 L : ; 6 D 8 6 B ? 6 D C 7 < 6 T D 8 A : 6 = 6

<

Vopt
7 9 6 ; 7

<

>

<

>

<

<

>

<

Table 15d Fig. 4 Table 15c

[ C L = 6 M

>

Ff

Work ar

Work Feed ar
Feed

D Cutter

Cutter

e
  +   + , , , ,

<

<

>

<

<

<

<

>

>

<

>

>

<

<

<

<

<

<

<

<

>

>

>

<

<

>

<

Ff
7 < 6 6 C 6

>

<

<

f
B @ D T

>

fopt
7 L U H 6 : D = D H

<

Vavg Vopt
Q @ 6 = 7 : D ; D C 7 7 L : ; 6 B > @ : ;

<

<

<

>

<

<

<

>

Table 15d
f
                       

<

<

<

>

Optimum Ff V
 

f opt
  

Average Optimum
                            

V avg V opt
         

(
 

)


Fd
   !   " # $      

F ar
  !

U 6

C D

"

Example 2, End Milling:

@ H D 7 = > 7 C 8 D 9 7 < 6 @ D H : B M : ; D K < L 8 B ; 6 @ @ D C ^ F F < ; > @ : ; ?

<

>

<

>

>

>

>

<

<

<

<

>

<

<

<

<

<

>

<

<

<

Table 11
9 6 ; 7 C L = 7 D S N < 6 = L

8 H L 7

B 6 7

optimum
C = > 7 C D 8 C > 6 L @ : ; 7 < 6

average
@ H D 7 [ 6 ; B 9 8 6 R : D > @ 6 \

<

>

<

f fopt
Q ; ? @ A 6 ; N

Table 15b Vavg Vopt

; B Q : ; > 7 6 7 D D H H :

>

<

>

<

Ff
G O

Fd
D \ : 9

<

Example 3, End Milling: ar

A 7 < D C = > 7 : @ F N F J : ; = < Y ; 6 ; B 9 : H H : ; ? M T < 6 ; 7 < 6

<

>

<

>

>

<

<

>

<

<

>

<

<

>

Fig. 4
] ; ? H 6 C L = P : ;

<

Ff
6 8 L : 9 >

Table 15c
M H B 6 A 7 < D C = > 7 L ; B 9 : ; : 9 > 9

<

<

<

>

Fd 15c
D 8 7 D 6 6 B @ L D T C 6

Table 15b
6 8 9 : ; 6 7 < 6 9 L ? L : ; @ 7 A 8 6 9 S

<

>

ar D
Q ; @ 7 7 D D L : ; @ 7 7 <

>

Table
L 7 < : ? < L 7 R 6 8 X

<

>

>

>

>

<

>

<

>

<

>

<

<

<

>

>

<

<

Ff
@ 6 \

<

>

>

Ff

Ff
g

&

<

>

fmax
L \ : 9 > N F J 7

>

Table 15c
L = 7 D 8 7 < L 7 = D > 9 C 6 6 B

>

<

<

<

optimum ar D
Q 8 L 7 : D M A H X : ; ? 7 < 6 ; N Q 7 D D 7 < L ;

<

<

<

<

9 G

<

<

>

<

>

fmax
B U 6 7 6 M 7 < 6

fmin
G ; 7 < 8 Q

>

>

optimum fmin
B ^ Z > 9 R L H > 6 M 7 < 6 C 6 6 B

: @ = P

<

>

<

ar D
Z c I N b F Z N F V I G

Vavg Vopt
Q I N F E M 8 6 Z ]

>

>

Ff
] Q [ F D 9

Ff
g O V G > @ : ; ?

Ff
C = > C

'

U 7 L

D 9

<

<

Fd
C D 8 = < D

Table 15b
M C 6 6 B 8 L 7 : D [ = < F N F G F

fmax
C 6 6 B N I O M @

<

optimum
A H 6 M 7 < 6 C 6 6 C D 8 L B 6 A 7 <

fopt
L 7 : D Z > 7 Z

>

<

Table 15c optimum

C 6 6 B ] 7 < 6 C 6 6 B C L = 7 D 8 ; L H = > 7 7 : ; ? @ A 6 6

<

<

optimum
I N I G F

<

fmax fmax
H 6 L B 6 7 6

6 N 6 B

Fd
W : @ D C 7 <

<

<

Table 15c
C 6 6 B 8 L 7 : D ; 6 6

>

<

<

Fd
6 ? 8 6

Slit Milling.
L ; ? H 6 = > 7 7 6 8 T : 7 < S < 6 ? : R 6 ; C 6 6 B @

<

>

<

<

<

<

D
B : L 9 7 D

<

<

>

<

<

>

<

>

>

<

<

>

>

Table 15c
;

15d
M

<

<

>

<

>

>

<

>

Fig. 5 Fig. 3
N M D 8 A : 6 =

<

>

>

>

<

<

Fig. 4
6 8 : @ C 6 B A : 6 = 6 M L

Case 1:
@ > 8 C L = 6 D C @ A 6 6 B @ C D 8

<

>

<

<

>

<

<

>

<

<

<

>

<

>

>

Table 15d
M 6 ; ? L ? 6 B : ;

<

<

>

V ar
:

Table 15d Table 15d Vopt Ff Far

C C M 7 < 6 ; [ C L A D 8 7 : D ; D C N Y ; B 6 7 6 < 6 H 6 ; ? 7 < D C = > 7 = 8 6 L 7 6 B

>

>

>

<

Fd
C 8 D 9 > 7 7 6

<

Far
7 < 6 =

<

<

Case 2:
9 : H H : ; ? M 7 <

<

>

<

>

<

Table 15c
< 6 = > 7 7 : ; ? B 8 9 : ; 6 9 L \ :

>

>

<

<

Table 15c
M > @ 6 B 7 D B 6 7 6 S < 6 @ 6 9 : ; : 9

<

<

<

<

>

ar
C L = 7 8 6 R :

<

>

>

<

<

Ff
@ H X M L H : B

>

>

<

>

<

<

<

>

Fd
@ ? : R

>

<

>

>

>

<

<

V Vopt Ff
Z

f Case 1
ar
Chip Thickness

Slit Mill

Work Case 2
f feed/rev, f
  +    *  ' &   '  ) & %  & $ 

ar

'

'

Avg.

Tables 15b

Z ^

Z ^

Z ^

Z ^

W U

V W

W M

Q T

N N

z P

c b

a ^

` a ^ ^ _ ^

a _ _ _

\ _ ^

c a a ^ a ^ a ^

Avg. Opt.

Z Z _ _

R W

Z _ _ _

c ^ _

c a

c a

P V N

Table 10. Cutting Feeds and Speeds for Milling Aluminum Alloys

f T ~ _

Q N

Metric Units: f

Z _

Z _

Avg. Opt.

Z _

\ ^ Y Y

Table 15c

Z a _ a

W Q

Z ^

Z ^

[ ^

W U

n W

o V W

S W M N O P

S f R

Q T

N N

V z P

Machinery's Handbook 29th Edition

{ n W

Avg. Opt.

U Z _ _ _ _ _

b _

b _

b _

b _

\ ^ ^

\ ^ _ ^

[ ^

c ^ _

U |

Z Z _ _ _

Z a

Table 15d

b ^

a g W U

t {

d S

Q T

O N

z P

W Z

Z Z _ _ _

Table 15e

Avg. Opt.

[ _ _ [ _ a _ a

c ^

Y f

Z _ Z Z

Opt.

` _ _ Z _ Z _ Z

^ Y Y Y Y

^ Y

q q q

O n n n

R v v

P q

T p N y y y

V T

W O

W W U h

U ]

f N

15c Slit and Slot Milling:

*
U Z R

\ T

M R W N Q

N Z ] n Z V W Z Z d

Z W O

a U

Face Milling:

n i

End Milling:

] n n n

P M T

N U

Z N

] O Y P a

V h

b N

U O P

` Y

N Q y

g k W

U R T

n i i i i

d Y

N ` T

f M Z M T M M M M M

Copyright 2012, Industrial Press Inc., New York, NY

f s

f s f s f s

f s

f s

Table 15b

Table 16

http://industrialpress.com

Avg. Opt.

Avg.

R e \ X

R \

<

R X

R X

R X \

R X

8 I

e \

X \ Y \ \ T \ Y

<

<

<

: O

<

<

R e Y

R Y

R X

R X

R X \

R X \

R X

8 Q

R \

8 I

Avg. Opt.

R c

H ?

X \ \ T \ T \

R e \

; :

d ]

R \

R Y ]

R Y

<

R X

R X

R Z

R X \

R X \

R X

R Z

R X \

R X

R X

R Z

R X \

Table 11. Cutting Feeds and Speeds for Milling Plain Carbon and Alloy Steels

Avg. Opt.

8 I

<

Z \ \

X \ T \ T \

X \ T \

Z \

X \ T

J <

Metric Units: f

<

: G K

R X \

R c \

R X \

R X

R X

R X \ T

8 I

Avg. Opt.

R Z

H ?

<

X \ \ T \

R e \

Machinery's Handbook 29th Edition

R Y

R Y

R X

R d

<

A K

Z Y

B L

Avg. Opt.

8 I

R ]

R \

R ]

<

d \ \

<

Z Y

<

R <

8 I

? G

Avg. Opt.

c \

R Y Y

R Y

R Y

Z ]

Z ]

R c

Z ]

Z ]

Opt.

c \

R \

c \

R \

c \

R \

f s

f s

f s

f s

f s

f s

f s

f s

f s

f s

R Z

R \

R \ T T

R Z

R \

R c

Z \

R e

: @

R = Y

R Y

R Y

R Y

R X

R X

X \ \

R X

A ?

<

; ;

R Y

R Y

R Y

>

8 R R X \ T T T T T \ T T T T T R R X R

W \ d W d W W d W

X Y

g X X W T T

? I

T T K

\ d W X W Y

W Y

R X

R X

T T

8 G T

T T T

A 8 ] X W

<

< ;

? T

\ W Z W X W e W Z W

T a B

R 9 : Z

<

T ; T

T c T W

L 7 8

T T

9 N

<

_ Y

W \

R Z B

<

: T

? I

X Y T T

<

<

` K

: ;

; G

T P a ;

Z A

B O 8

T W \ Y T W e W

8 G e W c W X W \ W

X \ T T T T T

: B B

g X X X

R Y

<

: ; :

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

Avg.

<

R X \

R X

R X \

R c

R c

8 I

e \

e \ Y Y

X \ T \ \ T

<

<

<

: O

<

R \ Y \

<

R X

R X \

R X

R X

R \

R X

8 Q

R \

8 I

Avg. Opt.

Table 11. (Continued) Cutting Feeds and Speeds for Milling Plain Carbon and Alloy Steels

R c

e \

H ?

R e \ \ T \

R e \ T \

R c

; :

R Y

R \

R Y

R \

R X

R ]

<

R X

R Z

R X \

R X \

R X \

R X \

R X \

R X

R X \

R X

Avg. Opt.

8 I

<

X \ \ T \ T \ T \ T \ T \

X \

R X \ T

J <

<

: G K

Metric Units: f

R c

R X

R c

R X

R X

R X

8 I

Avg. Opt.

R Z

H ?

<

R e \ \ T \

R e

Machinery's Handbook 29th Edition

R d

R X

R d

R Y Y

<

A K

Z Y

Z Y ]

Z ]

B L

Avg. Opt.

8 I

R Y

R c Y Y Y Y

R \

R \ T

<

d \ \

R c

c Y

<

Z Y

Z ]

T ;

<

R <

8 I

? G

Avg. Opt.

R Y Y Y

c \

R Y

R Z

R Y Y Y Y

Z ]

R c

Z ]

Z ]

R c

R ] \ ]

R X

Opt.

c \

R \

R \

R \

d Y

f s

f s

f s

f s

f s

f s

f s

f s

f s

R c Y \

R e

R d

R \ T

R e

R d

Z \

: @

c =

R Y

X \ \

X \ \

R X

R \ \

A ?

<

; ;

R Y

>

8 R X \ T T \ T R \ \

X \ \

W \

W Y

Z \

R Y

R \

R d

R Y

W Y

W :

Z \

R e

X Y

B Y Y

T j

R Z

<

I ;

T =

a B

a B

= 9 : Z \ Z R c

8 P a

R A

<

: W Y W d W Z W Y T W Z W W

< R Z \ Z d ] Y

< ? I ? I

N G R R R R R

O 8

8 G W \ e W Y W X W

8 G

Z \ \ Y

R ]

<

<

: ;

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

Avg.

R e

R e

<

R X

R X \

R X

R X

R X

R X

8 I

e \

X \ \ T \

X \ T \

X \ T

<

<

<

: O

<

R Y \

<

R X \

R X

R X

R \

R X

R X

R \

R X

8 Q

R \

8 I

Avg. Opt.

Table 11. (Continued) Cutting Feeds and Speeds for Milling Plain Carbon and Alloy Steels

R c

e \

e \

H ?

R e \ T \ \ T \

R c \ T \

R c

; :

R Y

R \

R X

R ]

R X

R ]

<

R X \

R X \

R X \

R X

R X \

R X

R \

R X

R X

R X \

R X

R \

R X

Avg. Opt.

8 I

R e

R e

<

X \ T \ T \ T \ \

R X \ T \ T \

X \

R X \ T \ T

J <

<

: G K

Metric Units: f

R X

R c

R X

R X

8 I

Avg. Opt.

R Z

H ?

<

R e \ T \

Machinery's Handbook 29th Edition

R X

R d

R Y Y

R Z

R Y Y

R Z

<

A K

Z Y ]

Z ]

Z ] ]

B L

Avg. Opt.

8 I

R Y

R X Y Y Y Y Y Y

R X Y Y Y Y Y

R \ T

R ] ]

R ] ]

<

d \

R c

R c Y

R c

R c Y

<

Z Y

Z ]

T ;

<

R <

8 I

? G

Avg. Opt.

R Y T Y Y Y Y Y Y Y Y Y

c \

R Y

R Z

R Y

R Z

Z ]

Z ]

R c

R ] \ ]

R X

R X

R ] \ ]

R X

Opt.

R \

R \

d Y Y T T Y T Y T Y T Y

f s

f s

f s

f s

f s

f s

f s

f s

f s

f s

f s

P Y

R Z

R \

T M M M

R c

R Y

R Z

R e

R d

R Y

R Z

R d

R X

: @

L Y Y

R Y \

R =

R Y

R X

R \ \

X \ \

X \ \

A ?

<

; ;

R Y >

R Y

8 R X R \ T \ T T

X \ \ T

X \ \

W Y

Z W

R Y

R Z

X R

W Y

W Y

T Z W X R T g T X R X X W Z Z \ W

R d

d Y ]

X Z d ] d

R Z R \ T T Y d

Z ] ]

R Z

>

g X

R Z

T @

R Z

R d \

W Y T

T R Z

R Y

d > >

T W \ X X Y W Z R Z d Y T T T R d

X B Z d ] d Z \ d X

d = g \

: B

d ]

R Z

Z Y ]

j Z _ Z

W Y

<

8 R Z

I ; >

W Y

W Y

a Y d

= 9 : X W R X R X R X R X W X \ T \ R Y

R d

R Y Y

R \ R Y Y ] R

R d \ ] d ] \ d X

T 8

Z Y ] ]

R Z

Z Y ]

R Z

X Z

R Z

Z < ?

R \

R \

W Y

W Y

W Y

g d

>

\ a B a B

R X

R X

Z \ \

R Y

Z Y

<

Z ]

W G Z Z Z Y : ] ] : R Z Z Z R Y Y ]

W W W Y

W R

O 8

R d

R \ R

R Y

R X

T W c W W Y W Y W c W Y W W Y W W c W X W W

>

>

>

j T

R Z

R Z

\ 8 T T T :

I g : g d Z c d d

d \ \ T T T T

^ D

Z ]

R Z

R Y ] ]

R Y Y ] ] ]

T g

B L

; :

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

Avg.

Tables 15b

<

R X

Avg. Opt.

8 I

X \

<

<

<

: O

<

c Y Y

<

R X

R X

R X

R X

R \

8 Q

R \

8 I

Avg. Opt.

Table 11. (Continued) Cutting Feeds and Speeds for Milling Plain Carbon and Alloy Steels

e Y

e \

H ?

c \ \ Y \ Y \ T

; :

R \ ]

<

R X

R X

R X

Avg. Opt.

8 I

R \

<

X \ T \ \ T

Metric Units: f

J <

<

: G K

Table 15c

8 I

Avg. Opt.

H ?

<

Machinery's Handbook 29th Edition

R ]

R ]

R Y

<

A K

Z ]

Z ]

B L

Avg. Opt.

8 I

Table 15d

R Y

R X Y Y

R ] \ ]

R \ T

<

R X Y Y Y Y

R c Y

<

Z \

Z \ \ Y

Z \ \ Y ]

T ;

<

Table 15a

R <

Table 15e

8 I

? G

Avg. Opt.

s Y Y

s Y

R Y

d Y Y

R X Y T ] Y

R X

R Z

Z ]

R \ ]

R X

Opt.

c Y T T T

f s

f s

f s

f s

f s

f s

f s

R d

R X

R Y

R d

: @

R =

R Y

R Y

R Y

R \ \

R Z \

X \

X :

A ?

Y < ?

; ;

R X

R Y

R Y

>

8 R \ \ ^ ^

R X

R \

R Y

<

I P

R \

= X t

: ;

W 9

R Y

; 8

<

<

I Z T

d X

d c

q Z 8 *

15c Slit and Slot Milling:

? P

d W Y n a

? W > \

n X

7 W 8

Z ]

n X

l n

l R

d 9

R = B A

<

8 9

R \

R \ T

Face Milling:

I V X W

; 8

W 9

End Milling:

Z X p

R Y Z

<

d Z

d R Z

Y B

= ? Z

o C

; :

u W

9 7

>

B 9 : R

R \ A

9 B

j R X B Z V Y W

I e ^ d E E \

<

T =

V < ?

X n

A W

< E

A ; 8 C

X \ Y

<

; n 8

Z ; 8 ; X

<

; 8

<

Copyright 2012, Industrial Press Inc., New York, NY

Table 15b

Table 16

http://industrialpress.com

Avg.

R X

R X

<

8 I

<

X \ = \

<

<

c Y

< U

R X

R X

R X

R X

<

8 I ]

H ?

R \

Opt.

e Y T

c \ T \ \ Y \ T

Avg.

; :

R X

>

E Z

<

= X

Opt.

R \ Y

<

Table 12. Cutting Feeds and Speeds for Milling Tool Steels

Metric Units: f

: G

Avg.

R X \

R X \

R X

R X \

R X \

R X \

<

8 I

Opt.

e \

e Y

R \

e Y

e \

e Y

X \ \

X \ T \

X \

X \

<

Avg.

Machinery's Handbook 29th Edition

<

8 I

B L

Opt.

R Z ] ]

R Z

Avg.

R X Y Y Y

Z \ \ Y

<

< < ?

K =

8 I

< G

H ?

Opt.

s Y Y

R \ Y \

A D ?

R X Y T

Y Q

Avg.

R c

R c

Opt.

f s

f s

f s

f s

f s

f s

f s

C :

R ] Y

R Z

R Y

R Z

R d

R Y

R \ Y

R d

R Y

R Z

R \

: @

R =

R Y

R Y

R Y

R Y

R Y

R Y

R Y

R X

R X

X \

R X

R X

R X

X :

A ?

R Y < ? Y Y

; ;

R Y >

R Y

R Y

R Y

R Y

8 R X R X R X R X \ T T T T ^ ^ ^ T T T T R X R R X

R Y Y

c W \

W T

C ^

X X

V Z W

g @

G Y d W d W \

K R

T z

7 C

V W

j c @ Z

W \

e \ R X

g =

W Y < T

j a

W @ V X O a @ C @ W \

E a

a E 7 d

W Y

W \

= 7

j L A

W Z

Z = < ? ? I 9 < ?

Z W T T K W

O W < 8 ? @ Y

? W W ]

@ z

8 h

q W _ T

R I \ ~

| d

; :

7 8 C G ? < W =

O \

Z Z W

E a V 8 V V W \ 8

l X Y

B W Z h 7

E a E

@ I E q

: B :

; =

<

I 9 :

<

< < 7

W ~ W

V I

<

? _ ?

l a B

? X W 8 h

W 9

q { W { W { W

<

W 7 7

{ ; ; ; W

{ W X @ @ W :

7 j L

\ I I I

L h l V } 8 ; : O a 9

7 I d

B L

l ; T _

W Y

<

8 A W a T

Z \

V G

| d W

| W \ T d X G

< _

= 7 ^ I O Y 9 | 9 | E 7 7 W

I \

< z

T ^

7 8

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg.

Opt.

Tables 15b

Avg.

R X

R X

<

8 I

<

O J

e Y

e Y

\ T

\ T

<

<

Z <

R Z

R Z

R X \

R X

R X \

R X

<

8 I

Opt.

R X

e Y

R X

e Y

c \ T \ \ T \

: ;

Avg.

R X \

R X \

<

<

<

9 7

8 I

Metric Units: f

: G

Opt.

Table 13. Cutting Feeds and Speeds for Milling Stainless Steels

X \ \

Avg.

R Z

R Z

Table 15c

<

<

8 I O

Opt.

R X

R X

Machinery's Handbook 29th Edition

B L

Avg.

R ] ]

R ] ]

Z Y

Z Y

<

<

8 = I

<

G 7

Table 15d

H ?

Opt.

<

R \

R \

Avg.

R ]

Z Y

R ]

Z Y

Table 15a

Table 15e

Opt.

R \

R X

R \

R X

f s

f s

f s

f s

C :

R ]

R d

R \

R e

R c

: @

] =

R Z ]

X \

X \

A ?

<

X \ > \ \

c \ \

X \ \

8 X X \ T T T

X \

R \ F

R \ Z W

g Z

l W

R X

7 e W

R \

<

<

R \ W

R \

: F

h M W \

R Z

R Y

= C W

W Y

R \

e = c W

15c Slit and Slot Milling:

R \

R Z

T R X

<

; B

Z X ]

W B \

P :

R \ Z

B = G

e :

W C

R Y

<

R \ 7 8

F : = X W

g d R

<

R \

Z W c W

W ;

<

Face Milling:

R Z Z

R X \

End Milling:

R \

>

Z W : F \ Z \ W

T T M

_ W

W X W W

R Z T

T ) B

R X

R X

R \

<

? R Z \

Z \

<

? 9 :

<

<

R \ 9 B

<

<

<

<

<

B B

<

<

<

: C

: C K W Z R \

O 8

h ?

W ?

= 9 : 9 Z W Y 9 W : 9 :

R X \

T _ < ? _ _

R \

R \ \

; : 9

Copyright 2012, Industrial Press Inc., New York, NY

Table 15b

Table 16

http://industrialpress.com

Avg.

Opt.

Avg.

Tables 15b

<

8 I

<

O J

<

<

Z <

R Z

R X

R \

<

8 I

Opt.

H ?

e Y

c \

: ;

Avg.

<

<

<

9 7

Metric Units: f

8 I

Opt.

: G

Table 13. Cutting Feeds and Speeds for Milling Stainless Steels

Avg.

Table 15c

<

<

8 I O

Opt.

Machinery's Handbook 29th Edition

B L

Avg.

Z Y

<

<

8 = I

<

G 7

Opt.

Table 15d

H ?

<

Avg.

Z Y

Table 15a

Table 15e

Opt.

R X

f s

R d

R Y

C :

R \

R d

R Y

R Z

: @ Y Y

L Y

c =

R Y

X \

R X

Z \ \

A ?

<

R Y

>

X \ T

X \ \

c W ^

R T Y

@ W

h ^ z

7 W

W @

: =

R Z

W Y

<

T Z

9 J

>

Slit and Slot Milling:

* I T R Z W I

<

<

7 ; 9

Z <

B P a

E 9 : _

l W

<

; Z J T

R Z

Face Milling:

End Milling:

c \

^ W

7 I V B 8 I W

= =

T I

? I

<

9 l Y W

15c

8 T

{ B < \

: =

<

; : h

<

; : c ] W

9 8

Copyright 2012, Industrial Press Inc., New York, NY

Table 15b

Table 16

http://industrialpress.com

Avg.

Opt.

<

Avg.

8 I

<

<

9 A

R ]

R Y

X \

<

< =

R X R X \

R X

R X

R X

R X

R X

<

8 I

e Y

] J

R X \ \ T \

R c \ \

R d \

R Z

R \

Avg.

R \

R X Y

R X

R Z

>

Opt.

R Y

: ;

R X \ \ T

Avg.

R \

R X Y Y

R X

<

R X e

R X

Z O

R X

R X

R X

R X

Table 14. Cutting Feeds and Speeds for Milling Ferrous Cast Metals

; 8 X

Metric Units: f

Opt.

R \ Y Y

<

R e

R ]

R c

J =

Z \ T \ ] \ \

X \ Y \ T

<

Avg.

: G

R X

R Y

R X \ \

R X Y

R X

R Z

R X

R X

<

R X Y

8 I

Opt.

R X

R Y

X \ \ T \

X \

X \ T \ T

<

Avg.

R d

R Y Y

R X X T

R X

R X

R X

R X

: N

M <

R X

Machinery's Handbook 29th Edition

8 I

H ?

Opt.

R Z

e Y

R X

R e e e Y

B L

e \ T \ \ T \

R e \

R e \ T

? I

Avg.

: V

? I

? I

<

K I

: =

I < 8 I

Opt.

: = _

<

8 M

: =

Avg.

; 8

R Y 7 8 = 8

E A

v _

R Y

R Z

9 < ?

X \ T \ \

= <

A = K

8 I u

<

; 7

8 :

H ?

Opt. Avg. Opt.

R X

R ]

R Y

c Y Y Y Y Y T Y T T

R e

R c \ \

R c \

Z \

R \

R e \

R Y \ Y \ Y

R \ Y

f s

f s

f s

f s

f s

f s

C :

R ]

R c

R Y

R \

R Y

R Z

R \

R ]

d Y

R Y

R d

R Y

R Z

R = Y

R X

R d

R X

R Y

R d

R Z Y

R d

R ]

R X

R e

R d

R \

R X

X \

R X

X \

R \ \

A ?

<

; ;

R X

R d

R e

R X

R Y

R X

R Y

R d

R X

R Z

R Y

R Z

R e

R Z

R c

>

8 X X R R X R X X X X X X X

R Y

R P

R d

X B

R c

<

R Y

B T

9 \

W \

<

R Z Y

<

^ R R

: ;

B =

Z Y

W : ; A R X

< T

] u 8 R

<

; :

<

R d

R c

u T

R Y

R d M

< d

u R 9 : \

^ M R Z Y A A R Y T < R e Z ^ ] W X W X

W Y M 9

\ <

R T

W 8 8 T W \

R \

R X

<

W Y Y Y

T ?

W Y

R c

R ]

R e

T R

^ T

R Z R X X R \ Z Y <

; =

R Z

R d : : : \

R < < < < <

9 h

j L

j L

j L P a R

<

<

<

<

<

~ P a

G B B B B P a

G B

R Y

G <

G <

^ < J 7 J 7 J 7 J 7 J 7 7 7 7 < <

? <

? <

W Y

9 <

: < <

R ] : F h : F : F : h :

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Opt.

Avg.

Opt.

Avg.

Tables 15b

R Y

R c

R X

R X \

<

8 I

R ]

<

X \ \ T

<

9 A

R d

R ] \

<

< =

R X

R X

R X

<

8 I

s Y

e \

e Y

e Y

] J

d \ T \ \

R \

Avg.

>

Opt.

: ;

Avg.

<

Z O

Table 14. Cutting Feeds and Speeds for Milling Ferrous Cast Metals

; 8 X

Opt.

Metric Units: f

<

J =

<

Avg.

R \

R Z

: G

Table 15c

R X

R X \

<

8 I

Opt.

X \ \

R X

<

Avg.

: N

M <

R X

R Z

Machinery's Handbook 29th Edition

8 I

Opt.

H ?

e Y

B L

X \

Avg.

R Y

R d

Table 15d

Z Y

: V

<

K I

8 I

Opt.

R X

c \

<

Table 15a

Avg.

E A

T J

R Z

Z \

Table 15e

9 < ?

= <

A = K

8 I

<

; 7

Opt. Avg. Opt.

8 :

H ?

R d

R X

R c

Z Y

R X

f s

f s

f s

f s

C :

R ]

R d ]

R Y

R c

R Y

R \

R = Y

R Y

R Y

R Y

R \

R X

R \

R \ \

A ?

<

; ;

R Y

R Y

R Y

>

8 R X R X X X X R \ T T T T

R Z

R X

R \

R Z

R Y X

R W Y T W T R \

R T X

R Z

\ d ] Y T

R Z

R \ X

Z ]

15c Slit and Slot Milling:

R Z

R X

R X

R X

R \

R \

<

R \ ]

Y T

R \ R

R ]

I 9 :

R =

Face Milling:

R a = W Y W Y W \

End Milling:

>

R X

\ T

R =

? I Z ? I = R ]

W W

? I

R X

R \ R \

R Z

? I

8 G

8 G

d K \ T K

X R

_ 8 G 8 G

W Y

<

<

R A A T

R Z

R \

^ \ T \

7 |

: |

: X Z ]

Copyright 2012, Industrial Press Inc., New York, NY

Table 15b

Table 16

http://industrialpress.com

Opt.

Avg.

Opt.

Table 15a. Recommended Feed in Inches per Tooth (ft) for Milling with High Speed Steel Cutters

Metric Units: ft

Machinery's Handbook 29th Edition

ft

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Table 15a. Recommended Feed in Inches per Tooth (ft) for Milling with High Speed Steel Cutters

Metric Units: ft

Machinery's Handbook 29th Edition

ft

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Table 15b. End Milling (Full Slot) Speed Adjustment Factors for Feed, Depth of Cut, and Lead Angle

optimum

optimum

Table 15a

Machinery's Handbook 29th Edition

Vopt Ff Fd

14

Vopt

Ff

Tables 10

14

V Vopt Ff Fd

Tables 11

Vavg Vopt

Fd

Ff fmax

optimum

Fd

Ff

average optimum

Fd

Optimum

Table 15c Table 15c

Copyright 2012, Industrial Press Inc., New York, NY

Vavg Vopt

http://industrialpress.com

fmax

Table 15b

Ff

V Vopt

Ff

6 77 6 fmax

ar D

Ff

Vavg Vopt

opt

Table 15c. End, Slit, and Side Milling Speed Adjustment Factors for Radial Depth of Cut

fmin

Vavg Vopt

Ff

ar D

Vopt Ff Fd

fmax fmin Ff1 Ff2 7.76 Table 15b fmax V Vopt Ff Fd

Machinery's Handbook 29th Edition

Fd

Ff

fmax

fmax ar D

fmin

Vavg Vopt

Table 15d

Ff

fmin

Fd

Fd

Slit and Side Milling:

Ff

Copyright 2012, Industrial Press Inc., New York, NY

Ff

Ff Ff

V Vopt Ff Fd optimum

http://industrialpress.com

Ff

Ff

Fd

V Vopt Ff Far

Tables 15b

Far

Table 15d. Face Milling Speed Adjustment Factors for Feed, Depth of Cut, and Lead Angle

optimum

Fd

Vopt

Machinery's Handbook 29th Edition

Vopt Ff Fd Far

Fd

optimum

V Vopt Ff Fd Far

Table 15a

Table 15e

14

Ff

ar Tables 15b

Tables 11

Ff

Vavg Vopt

15c Slit and Slot Milling:

ar D

Optimum

Copyright 2012, Industrial Press Inc., New York, NY

Case 1:

average optimum

Vavg Vopt Fd Far

Far

15c

Fig. 5

Case 2:

http://industrialpress.com

ar D

Table 15e. Tool Life Adjustment Factors for Face Milling, End Milling, Drilling, and Reaming
6 K B M O 6 B M 6 A 6 A 8 < 5 L 9 : : 9 ; > C 9 7 8 3 E 9 5 ? ; L 9 : : 9 ; > C 9 7 8 3 E 9 5 ? C 9 ? 7 R 3 9 : : 9 ; > 8 ; 6 6 M 6 P Q Q S B P Q Q 2 2 : H 9 1 5 G

T
I 4 9 ; = 7 5 ? J T U T @

<

>

fs
T V W T Z Z T

fm
T @ X Y @ Z Z T

fl
T Y X @ Z Z T

fs
T Z T Z Z T

fm
T @ [ \ @ Z Z T

fl
U T \ @ Z Z T

fs
T T T Z Z T

fm
T T @ [ @ Z Z T

fl
Z \ Z Z

Tables 11
     

#  
 

14
!     

Tables 17
     "     !  

23
      

&

'

T
   

VT fm V mum Table 15c

 ' , 
*     

VT fs V fopt fopt VT fl V
  
   ' , *
$ & ,     
      *             

#      

fopt
+   

"

'

fopt
  "

fopt fopt opti$ + * 

$ & . /         


fmax

Table 16. Cutting Tool Grade Descriptions and Common Vendor Equivalents
p g g _ i q f r ` h b s b j a i _ t u v f w ` l b j h d k i i l ^ _ ` a b m a b j h f n f e ` h f i j x ` j a w f y

Table 2
6 : 5 9 ; 1 2 3 4 6

791
; < = 7 7 6

Cemented Carbides and Other Hard Materials

? @ 6 B 6 B

>

>

<

<

<

<

>

>

Tables 1

4b 6
G

14

17

23

Using the Feed and Speed Tables for Drilling, Reaming, and Threading. Tables 17 23

Tables 17

23

Table 22

Table 5a

Table 15e

Table 5b

Approximate Cutting Speeds and Feeds for Standard Automatic Screw Machine Tools Brown and Sharpe

Feet Rate for Twist Drills

Q B I K 6 S B I R 3 9 : : 9 5 G 9 ; < 4 4 J 5 5 8 7 5 G 9 ; < 3 5 F 4 4 3 5 F J B

9 ;

I B T U Z Z Z T Z Z Z I Z Z U Z Z

<

J @ 7 2 @ \ 9 ; 3 5 F @ [ @ Y 4 4 3 5 F J

I B T U U Z Z Z Z Z Z I Z Z U Z T U

<

J @ [ 7 2 @ V 9 ; 3 5 F @ @ 4 4 3 5 F J

T T

I B U T Z Z Z ] Z Z T Z I Z T Z Z U

<

J @ 7 2 @ 9 ; 3 5 F @ @ [ 4 4 3 5 F J

I B T U ] Z Z Z Z Z T U I Z T Z

<

J @ X 7 2 @ 9 ; @ 3 5 F @ Y @ \ Y 4 4 3 5 F J

I B B U ] Z Z T Z Z Z U

I Z U Z ]

>

<

6 A B B B

6 B

6 B

>

<

6 B

6 B B B B

6 B

>

>

>

6 B

<

Example 1, Drilling:

Table 17

V Vopt Ff Fd

Vopt

Ff

Fd

Table 22

Avg.

   

   

    

Table 17. Feeds and Speeds for Drilling, Reaming, and Threading Plain Carbon and Alloy Steels

Metric Units: f

Avg. Opt.

 

  

  

Avg. Opt.

 

Machinery's Handbook 29th Edition

Opt.

 



 
  

f s

f s

f s

f s

f s

f s

f s

 

 

   


 

 

  

   

         

   

      





   

        

 











     

  

  

  

 

 

  

 

 





 

  

 

 

  


 




 

    

  

  

 

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

"

"

"

&

'

&

Avg.

 

 

* =

2 -

    

 

   

  

2 -

 

 

Table 17. Feeds and Speeds for Drilling, Reaming, and Threading Plain Carbon and Alloy Steels

Metric Units: f

Avg. Opt.

 

  

  

 

  

  

 

 

 

 

2 0

* C 3

* B

Avg. Opt.

0 D

             

      

 

>

  

 

Machinery's Handbook 29th Edition

Opt.

 

 

 

 

f s

f s

f s

f s

f s

f s

f s f s f s

f s

 

 

 

 


 

9 2

2 =

@ 5

 

 

 

>

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2   


 

 

 

 

  

9 ,

      

      

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f s

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9 




 

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(Continued):

 

 

   7 8 

 

<

 

 
 

1 2 

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) /

)   




   

 

 0 

+ ,

) 4

  

    2  

 9

3 *

* 

   

6   

* 2

/    

) 2 2 -

 

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

&

'

"

"

"

Avg.

Q K

 

G T

H T

 

 T V

o O

] G H

T I

X + ` ,

M g

M H M

* =

X K

2 -

[ 4 h e

G O

H G M H

I H X

V V U

   

X K

   

N K

2 -

I  ]

H O

  

H [ H ^

] V

Table 17. Feeds and Speeds for Drilling, Reaming, and Threading Plain Carbon and Alloy Steels

T R

K [ K

g T K

Q U U n I

I @

O [

R L

 H O L H

M U Q

S H H P

* G H

Metric Units: f

X O R

H L

F T

average

Avg. Opt.

H P O ]

  

 L

 T

Q H

I V

T W

R O       L

g U [

 

 

 V U

Q H T

 

 

 

 

  e j

H [

U c

O Q

2 0

X c .

X T

I J

* C 3

X P

U Y

O ) 2 Q

 Q 9 X V

Q 1

V U

* B

7 \ Q 1 2 I

X T

X K

L Y

/ Q H 2

o U J

Avg. Opt.

[ X    

N  



  T X

0 D

          

  

   

U Q I

N H K N

T I

V R I V

X Q

O  N

>

X H

 

Q
V U H

Q Q 2

Machinery's Handbook 29th Edition

T H

X K

M T

] H

Q M

O T I V

V T Q

T [ U

@ T U

O H P G H I H

e I

H O

c Q

9 Q

X X K H V U

Q M

Opt.

X K

I V M

 

  T

M Q G X

 




H K

S K

I H

f s

f s

f s

f s

f s

f s

f s

f s

f s

H P

X U O

X K J

H O

V H P 5 U

[ K

Q Q

I V W

T U T 

I + , G

 

H P


L

X U I   R K

V U M I N

9 2

Q X

[ S

e Q

T U

O q

2 =

Q Q L p

@ 5

U a V T R

G 

H V

H O  + ,  U

 H P

K K 7 7 7 7 7 L H

 

 

O + U X

G K K H O  

X K

V T

>

I I

u S

Q S

U I H Q

U H O

[      

V H K

 )    

T T L S

2    

  

 

Q S K

X H H K

9 ,

V + ,

M     

Q H Q        ; V  n

Table 22

average

Table 15e

H = *   
      P

H O

O I V

T U b

T Q

V W

H 

< 

R Q

V H T

U K

 T I X

I  T

  
 A

T H

U X

H 7

V L

T R

  

 U O

 O B

M U n


W

P O   U

X K

  

   1 I I I

V X K

+ 

N K    | T G H

H I H

 

     @ R X

T I

H P

< X U T N

2 R ~ O N

  

K I O

 X T K

> G  w H T

 

 : I

M [

O  

T F

6 T

Q  I

; 

H < 

   6 0 N  Q U

HSS Drilling and Reaming:

U X K

9 A 

| ) /

 ) / K

 )  A  2 )

T H

H P

{ * S

S U

* 

J K M

0 D

 

| H O

R Q

1 +

 1 2 


W G H

/   @ H

K F

 < *   

,  H

 T

V H

0 A

O @ 6

7  @ )   
 U

H Q k ]

H W

 

  2

O I V

) :

2 0

  1 2 y ,

) T

V H

0 1

H M

H S

1 *

a t

V U n

/ +




 /  | I N

  R [  7 ,

O Q

 

 T

)  , L H

U 2 ;

  

2  1  

H P

0 1

H P

 0

  

0 

 4  9

average

\ V

 

 5

2 

2 +

4 + , 

 9 + 5 ,

9 ; 

I ]

6  
9   F

X K

* < /

H P

w 1 ) /      , 

i ) ) +

i O

I < *

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

optimum

fd

Indexable Insert Drilling:

D Table 5a

1034

Table 5b Tapping and Threading:

optimum average

average

optimum

Table 16

Example 2, Drilling:

Fd

Table 22

opti

mum

fopt

optimum Vavg Vopt

Ff

Ff

Vavg Vopt

fopt

Fd

Fd

V Vopt Ff Fd N V D Example 3, Drilling:

Ff Table 22

fopt

Drill diameter 0.079 inch

Drill diameter 4.0 inches

Ff Fd V

Ff

Fd

Drilling Difficulties:

Drilling Holes in Glass:

"

"

"

&

'

Avg.

 

 

T ,

* =

2 -

M ?

2 -

 

 

Q   H

X [

@ 

= 

Metric Units: f

Table 18. Feeds and Speeds for Drilling, Reaming, and Threading Tool Steels

Avg. Opt.

H O

  

V W

H L

2 0

* C

2 9

* B

* T

 /

x , ,

Avg. Opt.

0 D

Q  

>

H P

Machinery's Handbook 29th Edition

H @

T H

Opt.

N K

f s

f s

f s

 L

W              

 

9 2

2 U

2 =

@ 5

  

 

 

  

H O

>

I 

 ) 

 

 

 [

      

  

 

 

   

9 ,

  ; 

 

*      







    

R O

>

 

<




= > =

 

? 

> 

<

= =

 

X K

>




<

= = 

<

>

) @

 

:  

 

<

= 3 = 

< @

 =

 

<

?   

 6 + 

 3  

@ 


5 K

2 < 

< 

I I

6 D

 :

4 @

<

V K

 , I

<

  9 2 

4 =

R < 

 2

3 

6 D ) 4 5  * 

K +

<

 1

5 

K 2 0 2 

5 )

J K

3 / + , + 2 1 2 < M

4 

0 L

, / 6 D 

, L

2 7 G . /   H

, 
< M

, 0

9 2 = 2

<

2 , 9 2

D -

1 1 *  . ) 2

<

 /

0 D H  6

4 4

* 9

 \

H k

4  9  )

) 1 2

<  1 =  ,  5

< 

+ ? < * / <

16

Copyright 2012, Industrial Press Inc., New York, NY

Table 17

http://industrialpress.com

Avg. Opt.

Table

&

'

"

"

"

Avg.

 

 

T ,

* =

2 -

M ?

    

    

2 -

Q H

X [

@  K

= 

Metric Units: f Avg. Opt.

Table 19. Feeds and Speeds for Drilling, Reaming, and Threading Stainless Steels

H O

  

  

 

V W

 

 

H L

2 0

* C

* B

s Avg. Opt.

0 D

 H

>

H P

Machinery's Handbook 29th Edition

H @

T H

Opt.

N K

  

f s

f s

f s

f s

f s

 L H

W  
   

 
 
 

 

9 2

2 U

2 =

@ 5

 

  

 

 

H O

>

 

                 

 [

2   

 

 

 

  

9 ,

  ;                       

 

 

 

 

  

@ R O

T 

2 @ K

<

 

 

I 

 

  

 

 

<

 

  =

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  U

@ 

i   <  

X K

 

v 1 M

 

  

) 

<

 /

 

: =  2 

) C

  

* 

< 

 

)  @ 

 

 

2 

<

* 1 2

 

2 -

0 ;

2 @

I I  } 

0  

0 

0 1

2 ) 

V + , K 

<

K 2 ) ~ + , :

3 

9 w ;

+   

2 

 0

C  

7
K 1 *

1 ) /

   

 4 *  0

K 0

2  @  

 J K

) M

 C

      L 

L 

 < /

, 1 2 K

 4

1 1 1 1

 

1 

1 

0 0

1 +  + +

+ 

3 *

 

, ,

, ,

,  H

2 ) 1 1 2 1 1 1 2 1 2 1 2 + D  V <


  \ H k

 =

 + ,

<

 

<

<

<

2 1 * 

16

Copyright 2012, Industrial Press Inc., New York, NY

Table 17

http://industrialpress.com

s Avg. Opt.

Table

"

"

"

&

'

Avg.

 

, + ,

9 3

    

  

  


@ 3

Table 20. Feeds and Speeds for Drilling, Reaming, and Threading Ferrous Cast Metals

Avg. Opt.

 


 

   

  

 

Metric Units: f

  

 

2 0

Avg. Opt.

 



 


2 )

* B

0 D

+ ,

) A

Machinery's Handbook 29th Edition

 /

>

x , 

Avg. Opt.

   

 

 

2 7 )

2 ) 

>

= * 7

Opt.

2 )

 

 

) < *

f s

f s

f s

f s

 

  

 

9 2

@ 2

2 =

@ 5

)    

>

f s

 

 

   


 

     

9 ,

 ;

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1 

 0

 

2 -

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 |

2 -

 7

+ 

 *

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<

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0 0 0 0 0

 2 2 2 

1 1 1 1

6 D * * * * *

6 D

6 D 

C ? ? ? 

 + 

+ < < < < < < < <

, +

1 +

2 +

 -

<

<

<

<

2  

2 

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Avg. Opt.

&

'

"

"

"

Avg.

 

 

Table

, + ,

9 3 T

 U

 

   

g  


 

Q H

V 2

X [

@ 3

K *

Table 20. Feeds and Speeds for Drilling, Reaming, and Threading Ferrous Cast Metals

T 8 

Avg. Opt.

Q   

 

 

Metric Units: f

H O

V W

 

H L

2 0

Avg. Opt.

T  

  
U

2 )

* B

0 D

H 1 2

+ ,

H P )

) A

Machinery's Handbook 29th Edition

 /

>

x ,

Avg. Opt.

T H

U      

9 N K

@ 2

Opt.

* C

 

 




f s

f s

f s

5 U

 

 

 


K

9 2

H O

@ 2

2 =

@ 5

) [

) 

  

> U

o T

R    

K i  )         

2 

  



 

  

 

9 ,

R O + ,

 

  

 

Q H

*  


 

   

V K

X K

 

 

    

) 




 

   

V K  

 

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 +

S T

  

O +

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1  ,
)

, 

1 +

K *

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<

* ;

,   

L * ,

*  +

* 

1 

G 3 3   

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 +

 * 

*  O

, +

2 + 9 9 

 
H \ k

<

<

<

2 

 

/ 2   2

16

Copyright 2012, Industrial Press Inc., New York, NY

Table 17

http://industrialpress.com

Avg. Opt.

"

"

"

&

'

Avg.

 

3 5 I X

O i

v @

* =

 X K

W ?

    

      

2 -

V K

 
   

 

 

T 

J K

Metric Units: f

Table 21. Feeds and Speeds for Drilling, Reaming, and Threading Light Metals

Avg. Opt.

 

    

H k

  

 

H \

f ]

L   

1 2

  

 

2 0

 

, T

* C

H 3 P

2 9

* B

M 7

* X

U 9

 /

Q o I

Avg. Opt.

H [

 


 Q H

0 D

 

 

 

>

Machinery's Handbook 29th Edition

L V

T @

/ T

= K

9 Q

Opt.

/ K

, H O )

1 

 

  
  

 

3 * C

f s

f s

f s

f s

f s

2 +

T >

5 ,

, F

<

 

9 2

@ 2

= V

J )

 + 

V -

>

: ? : : : H P 0

) @ : : O

) 9 R

>

C o

` 2 C

>

9 ,

, C :

* *

* :

T H

0 V

N K

 )

+ ,

1 H

 0

L * 

T H

 9

3 /

O V 6

I )

3 *

V T

1 H O

0 -

[ < *

6 S ) 2 * 

* O

3 

* 9

Q 

2 +

) I

* 0  

3 * 3

T T 9

, 2

 

U K

9 5 , T

* 0

3 * , , , 3 X

V U H

* 

5 ,

 T

2 +  n 

3 * 5 5

H *

X W

2 0

 

W 4 2 0  R O

0 /

0 /

1 6 ) 6 6 6

* 

Copyright 2012, Industrial Press Inc., New York, NY

Table 16

X [

http://industrialpress.com

Avg. Opt.

Table 17

&

'

'

"

"

"

I K K O

X K e

L I U

M W I V

N  c s   h c

U d j O

N K

h c

d s

V M L

J K H X I

M I N

c H [

c X

I 

V L

X H

K I H O I H

V O

Q L

L X

S N K M H

G U

d s

d I

i V R

H P

T H M

 j

d s i

O Q

N U

X H P ] s  T

S K

T S

n M H

H H

k O

a W O

G U I

Table 22. Feed and Diameter Speed Adjustment Factors for HSS Twist Drills and Reamers

U h  h d c  h c

H i i P N

Fd

V c  j d  s i c j d U

K H O

] c

5b

L I

X K I

I U  ]

V  L

K Q Q X 

N K

N K

b X k

\ T

X X

X V

N O  U

Tables 5a

Y O H

U h c  c c  d 

X U

m K

Fd

h s s

 j

V X P

O H X P T o

H P P

] h

V U

Q O

X K

H P

N [

H P

H H W

V U

Q k N F V ^

b T

[ K Q

H O

V U Q

T ` U c c c c c c c c c c

N G ] H

H I L T O H I S K I H

23

R M I W

i i i i i i i i i i

S I

O H

e I V

G F

R K

H [

V U

optimum

S K I

V H U

H P

K V I

U  j M i c h   c  c

I K

X K c H O i L

 j j j j

Tables 17

Machinery's Handbook 29th Edition

Vopt Ff Fd

c i i

S O

H O O o

X Q V W I

L H

L H

X H

U d      d

I N O

N V

T [

V U I

I N d d d   j U  h

T U Q

U h G H

] O i U

L T

I L L L

L L U

U U

V U Q X

Q Q X

X N

X o k

I K k

Vopt

T L

T W

U U  d j h c  d h d U I

N    d d   h

R K K

I I J U

i X Q

H N c ] c ] c ] c ] c ] c ] c ] c ] c ] ] Q I I H

[  \

H P

\ g

\ H

\ H

H P

I T

X K

K X K

H P

M U c h  j h  s  s M 

V Vopt Ff Fd

I N  j s s s s  d h j

X O

M I c H V

I S

] M G H

N Q V U c ] K X

Q g

X K

Q M

X Q

X K

R T

M c c H

V c c  s H P  c c d

d j

H P

d j

 O

H Q O

J b K

] j

i L Q S

K H K X

H H P K

H U

O I F

W R H

J N K

T G H

Q Q

 j s

 j

i M

I X

T H

O H

T H H s i i i i ] ] ] ] ] h ] s ] s ] ] d ] j ] I

U G

U H P U

X W U

W I

K I M

T V P T

c j

c j j

d I

V L

N K

H O

Ff

 s

N K G H

H [

o h ] ] ] ] h ] h ] s I i i i i L M ] s ]  ]  ]

R O I

average optimum Vavg Vopt

K H P

X K

V H

F V I S L O

c s i

 j j

H W

Q d c T

c s i

V ^ V

I U

H Q H Q

I M

M V T

H O W K

H O  c

H ^ X

S K

c s i

 s j

H P

X K G R

H H

I I

f V

h s s

 I [ U K

i I

U U

U L

T I

M R

Ff

S G

U I I V

Q R

X M K

H Q X

f G K c c c c c c c c c c c

I H P

I U k

I I

U ] ] ] ] ] ] ] ] ] ] ] U

R T

O V

X K

a H O

T H

H N

Optimum

N M

H L S G H H K

H c c c c c c c c c c

O X U G h O e

H K O

 j

 s

U H g I

X K

O G M

m ] H ^ i Q c ] c ] c ] c ] c ] c ] c ] c ] c ]

H I

H ^

K M

K M

O V

I U

Copyright 2012, Industrial Press Inc., New York, NY

optimum

Table 15e

http://industrialpress.com

Table 23. Feeds and Speeds for Drilling and Reaming Copper Alloys
Group 1
           ! 

"

"

Group 2
     #         $   #  

"

"

"

"

"

&

'

Group 3
            % #    #      #  

&

&

&

&

'

'

&

&

f Metric Units: f Opt. Avg.

Opt.

s Avg.

Opt.

Avg.

f s f s f s
  

HSS Drilling and Reaming:

Table 22

optimum

average

Table 15e

Indexable Insert Drilling:

Table 5a

2D

Table 5b

Table 16

Using the Feed and Speed Tables for Tapping and Threading.

Tables 17

23

Tables 17

23

average

optimum

Example:
3

Table 19
2 1

Table 19

Cutting Speed for Broaching.

<

>

Spade Drills

Fig. 1 Figs. 2a
6

Fig. 2f

Body diameter Coolant holes Blade retaining screw Locating flats Body

Milling machine taper shank

Morse taper shank

Flute Blade slot

Seating surface Flute length Coolant inductor

Straight shank

Automotive shank (special)

 

Spade Drill Geometry.

>

Typical Spade Drill Blades

Fig. 3

1 C

>

>

Fig. 4

Rake angle O.D. clearance angle O.D. land (circular) Blade diameter

R Radial rake Front lip clearance angle Chip splitters Seating pad Locating ears

Flat rake

Chisel edge angle Chisel edge Blade thickness 0.031 Typ.

Web Rake surface Cutting lip

Locating slot

Cutting edge angle Stepped O.D. clearance 0.031 R. Typ.

Back taper Point angle

O.D. clearance angle

Wedge angle (optional)



Spade Drilling.

>

>

Tables 17

23

1060

1078

&

'

"

"

h d

h d

h d

c b d

g d

h d

h d

h d d d

c b

^ f n f n f n f n f n f n f n f n f

] g

] c h c h c h c h h h b ] ] ] ] e h h b ] ] ] ] ] ] ] h h h h h h h h h h h h h

h d

h d

h d

h d

c b d

c a

h d

c d

c d d

c d d

c b b

a [

h d e ] ] ] ]

U d d d

c b d

c d

c b b

c a

c b

c d

c d

h d

c d

c b

c b b

M f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f n f

M N

M [

K O

e b

h b d ]

e b

h b

M i c c c b b c c b c c b a c b a b b b b h d c c c c c c c b d d c c c b h d b b

^ R M f n f n f

e b

h d ] d

f d

f b

f d

c b b b

c b

a b b

a b b

a b b b b

c d b b

c b b

c b b

c b b b b d

c b

^ f n f n f n f n f n f n f n f n f n f n f n f n f

b f

h d

f d

f d

f d b d

f d d d ]

f d

f d

f d ] ]

f d ] ] d

a b b

a b b

a b

a b ] b ] b

a b b b b

a b b

c b b b

c d

Feed Rates for Spade Drilling

Machinery's Handbook 29th Edition

f d

f d

f d

f d

a b b

a b

a b

a b

c b

f d

f d

a b

a b

S O

h d e

f e e

c e

N M

a k

a ] ] ]

a ]

[ M

\ b ^

M i

e b

h b

h d

u d

c b

c a

a ]

c d b

f d

e b

f e a

a ]

f d

f ] ^

f d d d d

f d d

f d d

f d

f d

f d a d d

f a

u d

a b

a b

a b b ]

a b

a ] ]

a b ]

a b ]

V f f f f f f f f f X ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ r K

f d d

f d ^ ^ ^ d ^

f d ^ ^ d ^

f d

g d d

g d

f d d d

u d

K a a a a b ] ] ] ] ] a b ] ] ] ] ] ] ] ] ] ] ] ] a a a a a

S P t

N r

K }

S O

M T

r m

P N

P L M

 T

M T

M N

O M

S K P

T S O

K m L M m M m

L r t L S X R { {

T L M P P

N M Y P X \ \

S x O S O S

t S N K

P N \ O M \ O

~ x N N r

r N r L L

o S

O M

S O P N T y M

S O O

L K

L [

T q r

P w O P N O [ Y

\ O M

M \ N \ T w

L r P x M T O O O

N M

M S

S S

q O R K r L L L

P X K p J K J K L M \ R \ p X Y N K O K O L M L M O L M L M

N v M

N P

T O

O M

M r W z t L M K K K W z

r \ P

Y M i o M i M O S i m M S

S X X Y

Y N K r

N M K

N M

M N K O

p v

r v

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

>

>

Power Consumption and Thrust for Spade Drilling.

6

Table 24

em

D fN

D fN

Bs

( fD )

Bs
m

fD

em

em

fm N

fm N


hpc = hpm = Bs = uhp = D= f= fm = N= em =

kwc = kwm = Bs = ukw = D= f= fm = N= em =

Table 24. Unit Horsepower / Kilowatt for Spade Drilling

Example:

Table 17

1060

Table

1078

Table 24

>

V D

N= V= D=

D fN

em

Bs Bs

fD

Trepanning.

<

ESTIMATING SPEEDS AND MACHINING POWER

Estimating Planer Cutting Speeds.

Vc Sc L
6

Vc Sc L

Vc = Sc = L= Cutting Speed for Planing and Shaping. Tables 1 4b Tables 6 9

6

1026 1038 Tables 5c

Cutting Time for Turning, Boring, and Facing.

L fN

Planing Time.

Vc W
6

Vr

W L V F c

V r

Speeds for Metal-Cutting Saws.

1082

1180

Speeds for Turning Unusual Materials. Slate

Rubber

&

'

Speeds, Feeds, and Tooth Angles for Sawing Various Material with Solid-tooth, High-speed-steel, Circular, Metal-cutting Saws

O e [ k k

O [

S [

S O

S O k [ [ [ [ [

O [

O [

S O

[ [ [ [

h k k k k k k

a R

c d

u d ] d

c d

f b ]

f b

g b

u d ] d

e b

R O S O S

[ [

b S T O O S O S O S S S S O O S

M [ k k

O [

O [

M N

\ r

m k [ [ [

S [

O [

S [

S [

S [

[ N M

M T

[ M e m

[ u u f

R U

a U P

c d

h d

u d

h d

f d

f d

f e

M x ] S a u d d ] d

u b ] ] b b

T Y \ N r

K V

[ M

M P

\ {

K O S O S

m [ [

O K

S O O

S S

b S O [ k [ k

S O [ [

\ L M [ O L k [ k [ k [ k [ k k k k k

O k k [ [ [ [ [

S [

S [

S [

S [

[ [ [ [ [

k k k k k [

L r

y p {

[ [ [ [ [ [ [

k M

L f u h

= =

u d

f d b

f d ] d ] ] d ]

u b

h d

c a ] ] ] b

h b

c b

O [ k [ k k

] O [ [

[ [

1036

S O k k [ [ [ [ [ O

S O [

O [

O [

[ [ [ [ [ [

[ h

u d

f d ]

f b

c b

h b

c b

Machinery's Handbook 29th Edition

[ U [ [

S O

S O

S [

S [ [ [ [

[ b

Table 6

Y S

T k

T [ k k k k

f Y Y Y Y

k O

O f

O f

S f

S f

S O f O

S O f f

S f

b ] ]

O f d h f d f a a f f f e d h

f b

g d

h d ]

n e a e a b d b ]

h b ] d

n d

n d ]

[ U

T _

a O

S [ O

S [ [ [

[ [ [ [ [ [

Y S O

T T T T k T k k k [

k ^ k k k k k O S

f Y Y Y Y

S O

S O O

] T T T T

S S S S S S

O O S f

O f

O f

O f

O f

O f d

g d d d b

O f f f b d c f f u f d f

T U

e b

h d ] ]

a b ]

n d ] b

g b

n d ]

[ M

S [ [ [

[ k

Y S S

L r T T

T T [ T

k O

^ Y Y Y

k O

S O S O S

O f

S f

S f

S O O

S O f f

S f f

g b

O f a d b d ] ] h c c h S O f b S f d d h b

e b

a b

h a

n d ] ]

S [

S [ [ [

Y S S

O k

T k

T [ k k k

O f

S f f f f Y Y Y

_ O

k O

O f f f

S f

S f

S f

S f

O f

S f f

b ]

O f d h f d h b c b c f f b

S f h h

O h

n a n

h b ]

n d

M a f f

f d

e d d

a ] ] ]

a ] ]

O m U

P U

Gutta percha

P K

M L M

Limestone

M T T T

N r

Copper

M T L } M

K X

N K

S T P r P r X

M V

N r

T s s L { M

N K V p

P [

M S

Y S N N O

z Y N K N P { r

M K

| K

Copyright 2012, Industrial Press Inc., New York, NY

Marble

http://industrialpress.com

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Estimating Machining Power

Kp

Tables 1a

1b

Table 1a. Power Constants, Kp, Using Sharp Cutting Tools

Kp
! ! , , 

Kp
! , 

Kp
! ,

Kp

Ferrous Cast Metals

  !

>

>

Table 1a. (Continued) Power Constants, Kp, Using Sharp Cutting Tools
Kp
! ! , , 

Kp
! , 

Kp
! ,

Kp

High-Temperature Alloys, Tool Steel, Stainless Steel, and Nonferrous Metals

   

"

'

Table 2

Table 3

>

>

Table 1b. Power Constants, Kp, Using Sharp Cutting Tools

Kp
! ! , , 

Kp
! , 

Kp
! ,

Kp

Wrought Steels
+ 

 

 

  

 

  

Table 4

Table 5

Pc = K p CQW Pm =

Pc E

K p CQW E
6

Pc =

>

>

Table 2. Feed Factors, C, for Power Constants

, , !

C


C
% 

C


C
% 

Table 3. Tool Wear Factors, W

*

&

"

&

&

Pm = Kp = Q= C= W= E= V= N= f= f=

Tables 1a
6

1b

Table 5 Table 2

Table 3

Table 4

>

>

ft = fm = dt = d= nt = nc = w=

Table 4. Machine Tool Efficiency Factors, E

Table 5. Formulas for Calculating the Metal Removal Rate, Q

    
 

    


Q

 
 



  

   

Vfd

fd

fmwd



f m wd ,

Vwncdt

un c d t

Example:

Kp = C= W= E= Q= Q=

Vfd

Table 1b Table 2 Table 3 Table 4

Table 5

Pc = K p CQW Pm =

Pc E

Kp = C= W= E= Q=

Table 1b Table 2 Table 3 Table 4



fd

Table 5

>

>

Pc = K p CQW Pc E

Pm =

The life of a cutting tool is most affected by the cutting speed, then by the feed rate, and least of all by the depth of cut.

Example:

Kp = C= W= E=

Table 1b

Table 2

Table 3

Table 4

Q max

Pm E K p CW

P m Q

K p CQW E

Q max fd

fd

Example:

Kp = C= W= E=

Table 1a

Table 2

Table 3

Table 4

>

>

Q max fm N

Pm E K p CW

P m

K p CQW E

Q max wd f max ft nt

(Q ( fm N

f m wd ) ft nt N )

DN

V D

Estimating Drilling Thrust, Torque, and Power.

Tables 6

Table 3

wd Table 7
/

cd

cd

cd

Table 6. Work Material Factor, Kd, for Drilling with a Sharp Drill


  

Kd

      " 

   

&

'

 

   $ 

a a

'


! ! 

c
 

+ 
*

c
$ 

'

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Table 7. Chisel Edge Factors for Torque and Thrust

/ / . 0 0 0 . 0 0 0 -

cd

wd

cd

wd

cd


cd

cd wd
/

"

T = Kd Ff FT BW Kd M =KdFf FM AW Pc =MN
0 / 4

JW

T= M=

Kd Ff FT BW K d F f F M AW

Kd D JW

Kd Ff FM AW

Pc =MN

Pm

Pc = M= T= Kd = Ff = FT = FM = A= B= J= W= N= E= D= c= w=

Pc E Pm =

Table 6

Table 8

Table 9 Table 9 Table 7 Table 7 Table 7

Table 3

Table 4

Table 7

Table 7

Example:

Kd = FT = A=

Table 6 Ff = Table 9 FM = Table 7 B =

Table 8 Table 9 Table 7 J =

Table 7

>

>

Table 8. Feed Factors Ff for Drilling

1 1 0 2 0 2 0 2 0 2

Ff

Ff

Ff

Ff

Table 9. Drill Diameter Factors: FT for Thrust, FM for Torque

1 1 4 4 4 4

FT

FM

FT

FM

FT

FM

FT

FM

W=

Table 3
2 2

T = KdFf FT BW Kd d JW

M =Kd Ff FMAW

V D

>

>

>

MICROMACHINING
Introduction
0

Machine Tool Requirements

4

Fig. 1a

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Fig. 1b

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>

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>

{ B C

>

<

>

>

Y [

>

Z B B

>

<

<

>

&

Example 1, Spindle Speed for Macro vs. Micro Machining:

  "

1049

Macromachining:

V D

( )

(
7

Micromachining:

V D

( )

( )
7

Microcutting Tools Tool Stiffness.

<

2 /

Example 2, Stiffness of Microtools:

(D )
2 3 > 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

(D )
4 3 3 > 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 7 6 6 6 8 6 9 6 6 6 6 6 6 4 3 :

>

<

(D )

E
? : 6 6 6 6 8 6 @ 6 6 6 6 6

(L )
? 2 > 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

(L )
? 4 > 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 2 ? 4

>

6 7

(L )

Tool Sharpness.

Figs. 2a r

2d

Chip load
                      

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&

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f
 

>

c L nN

f= cL = n= N= Example 3:
           
  
 
  ( 
 #   

&

Table 13b
 
      

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V D
6 6 6 6 6 6 6

>

6 6 6 6 6 6

<

6 6 6 B 6 6 C 6 6

>

F 6

'

>

c L nN

>

6 6 6 6 6 6 Q R R

,
@ 9 M 7 7

>

<

,
@ T 7 7

6 6 6 6 6 C 6 6 6 6 C E F

C 6

<

F 6

Effect of Depth of Cut (Chip Load) in Micromachining

{ v | } y u ~ v r } s v }  | z v x u w r q y q q z

} z z q

t r u  |

v t y

r
p q r s t u v w v

r

         
   

r
  
% 

Figs. 2a
          m      

2c
     

Figs. 2b
      

2d

Fig. 6

Figs. 3a

3b

Tool Edge Measurement by Atomic Force Microscopy

n      
       %   
       
"          

Tool Materials.

Fig. 4

&

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Example 4, Required Included Angle:

Solution:
L

Fig. 5

Table 1

B

Fig. 4

Fig. 6

Table 1. Commercial Coatings for Microtools

!  
  i 

e
g

 & k o

1 &

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

Tool Offset and Positioning.

b a

e
g

  
$ ! ( !

&

Example 5, Sensor Requirement: Solution:

>

6 F

N u

M 6

7 6

>

>

@ 7

Fig. 7a

Example 6, Lateral Tool Offset Calculation:

Solution:

L
{

L L D
{ x w

D
L

Fig. 7b 7a

Fig.

   

Example 6

Fig. 8b

Fig. 8a

Fig. 8b

Machinery's Handbook 29th Edition

     ! " # ! $ % % & ' % # # ( )

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<

>

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<

<

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Example 7, Vertical Tool Offset Calculation:

T O K P P K Y Z [ \ ] M V K L O N W U O Q W O N Q O S T M R S W ^ U O T U T K R Q U d d M M Y e S U P K X K M T U R U O M X M O M Y L M f K Q L U Y M S R M T Q N X K

h
Q ] M k S

Fig. 9
K Y L ] [ d

h
l ^ ] M

h h
l

Tool Damage.

Table 2

Figs. 10a

10d

Mechanical effect

h h

<

Microtool Damages
 

3
* + , / > 2 / 7 + 3 9 + 4 < @ 2 3 , 2 8 7 7 + 8 8 / 2 * + , > = + 5 4 = @ 8 : , 8 / 4 / 1 = 4 4 + 9 , 5 + @ 6 2 3 ; 1 8 9 4 8 2 4 3 8 : , 8 5 / > 8 5 : = 8 4 3 / 9 : 7 + : 8 5 / > 8 5 3 6 / ; + 1 2 3 : : + 6 6 8 2 8 9 4 1 = 4 4 + 9 , 7 @ 8 8 : 3 9 / ; + 1 2 3 : 2 + 5 5 -

> 8 5 -

4
6

5
* + , 1 : < 8 7 + 3 9 8 / 2 5 / > 8 5 : = 8 4 3 * + , : < + @ @ + 9 , / 4 4 < 8 1 = 4 4 + 9 , 8 : , 8 3 6 / 1 / 2 > + : 8 > = + 5 4 = @ 8 : , 8 3 9 / ; + 1 2 3 ; + 5 5 5 / > 8 5 ; + 1 2 3 ; + 5 5 : = 8 4 3 5 3 1 / 5 : 8 @ 5 8 4 + 3 9 3 6 1 3 > / 5 4 > + 9 : 8 2 -

Thermal effect

"

Chemical damage

Adhesion tool damage

Table 2. Categories of Tool Damage

/ ; / , 8 7 +
0

<

; > 2 / 7 + 3 9
1

+
1

<

<

<

<

<

<

<

<

<

<

<

<

<

Tool Life.

' (

&

"

'

Tool Life Testing with Single-Point Turning Tools

'

'

&

&

"

"

"

Table 3. Microtool Wear and Monitoring Techniques

0 8 / 7 = 2 8 ; 8 9 4 0 8 4 2 3 5 3 , A
9

<

<

>

<

<

<

9 4 8 2 6 8 2 3 ; 8 4 8 2

2
/

<

>

<

<

MACHINING ECONOMETRICS

1132

Va fb dc T

V= f= d= T= g, a, b, c =

"

"

"

"

"

"

b c

Equation (1)

Va T
&

g fb dc

"

VT n

g n f b d c

Econometrics

C
7

b c

fb dc T
!

g Va

Equation (3)
&

&

&

&

&

&

&

&

&

t T
"

t T
D D D D D C

t T
D D D D D E

tk Tk
D D D D D D D

ti Ti
D D D D D D

Q
F

G C

Q Equation (5)

Equation (3)

ti Vi
C

QC

G C

Te

Te
Z [ K K L M N O P Q K R S S T T Q W X K K V ] M W S X ` T V M ^

ti
i
K S [ G C K W P ] K S T T Q V P ] P _ K P W P S T T Q P U S K ` ^ M ] M Q P S N R N R

Equation (6)
I I

Q
i
f T Q O N R _ U T ` S [ K K L M N O P Q K R S

ti Vi
C G C ^ M S S N R _ W X

C Ve
k

Te Ve
C

Ve

ti Vi i k Q ti
C i G C D D D D D D D D D D D D D D D D D D D D D D D D D D D D

i
^

n
D _ K

G C

b h

Q
K ] N R _

S H i

Ve
T V K Q W R W j R P

n
U

Vi
o V K ` ] N Q Q N R

n
N O

Equation (6) V Vi
N g W S N S M S K j H I

Equation (6)

V
g p q T ` V ` N Q Q N R _ j S T T Q o K P ` o T M Q V

n i
K ] T

ti
G C g W S W M W S V N W ^ T R

QC
P R S N P Q

Equation (6)
m Q N R K P ` Q U ` T ] S

Equation
T M S K ` ] T W S

(9)
p q T ` P V N

Vi
Q P S N O

i
p q T ` ] N Q Q N R _ j S [ K P ^ S M P Q ] P Z [ K ^ [ N X _ K R K ` P S N R _ S N ] K N R G C ^ [ N O T

ti Vi
C R N R _ S N ]

n
D D D D D

n
K N W S [ K S N m

QC
] K

ti Vi
C

M
i I I

QC

D D D D D D | w

a D
D D D D D D D D D

G C

= a= M= D=

Example 8, Cumulative Tool Life: Turning Test:

N W h U Y

n
T g K R

Table
[ \ ] M

4
R P

Equation (3)

(V V ) (T T )

( (

) )

n
M U

Table 4
S R M Q ] M R M

t
f U Y T U Y Q L S

tV
M M e S K Y Z R W

Te
O K V M T U Q U

Equation (7)
P T U Q U U Q L N Y R Q K Y Q R X K Q Q K Y Z N Y

Ve
Q K J M J U P

Equation (8b)
M M T R K R R ] N ^ Y K Y r N X L S V S P U Q K J M

Fig. 11a
Q N N P P K X M V V M V U Q M O K

Facing Test:
Q N N P P K X M W P N Q R U O U Q P N ^ Q ] M Y ] K Z ]

Figs. 11b
Q ] M N Q ] M O ^

11c
U O N S Y

Table 4. Spread Sheet for Example 8, Cumulative Tool Life in Turning

Ve

Te

tV

/n

tV

/n

Workpiece Materials
g n N ^ ` T ] P ^ [ N R N R _ N W T U S K R M S N Q N v K V S T U P ` N ^ P S K ^ T ] X T R K R S W U T ` ] N R N P S M ` N v K V W K R W T ` W j ] K V D N ^ P Q j T X S N ^ P Q j P R V K Q K ^ S ` T R N ^ V K O N ^ K W j K S ^ Y T ] ] T R K R _ N R K K ` N R _ ] P S K ` N P Q W U T ` S [ K W K P X X Q N ^ P D

'

&

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<

'

&

"

>

'

&

 

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Example 9, Grain Size Consideration:

1049

Macromilling:

Micromilling:

Table 13b

1131

Ductile Regime Micromachining Crystallographic Directions and Planes.

o T ` s X N K ^ K P S T ] T ` N K R S P S N T R P U U K ^ S W S [ K ] P ^ [ N R m K ` S N K W ^ [ P R _ K o N S [ ^ ` W S P Q Q N R K T ` N K R S P S N T R Y g h [ K R ] P ^ [ N R N R _ N R ] N ^ ` T T ` R P R T W ^ P Q K j S [ K g N R _ X K ` U T ` ] P R ^ K K ^ P M W K S [ K ] P S K ` N P Q X ` T X D

Figs. 12a
S [ K W M ` U P ^ K j P R V N W ] T

12b
S [ K W N V N U U N ^

Fig. 12a
S [ K W P ] K m ^ ` W S P Q Q T D

Fig. 12b.
S N T R W T U P S T

m n

Fig. 13a
j

H i

"

&

'

'

'

m f

Fig. 13a
j ^ S T ` o N S [ ^ 5 6 7

[
V K

<

,
+

<

,
b T

<

]
T

[ , , ]
d S [ K R S [ K

[
n

]
Q K `

>

m f

[
K W K

<

,
K

<

,
W

<

]
N R S

[ ,
K ` W K ^

<

, ]
S o N S [

[
S [

]
T T

>

m n

Fig. 13a
j n K W Y Z [ K N Q

8 C D 6

N R

E 9

>

>

y
j

>

>

z
K R ` S

>

>

E E + j N R S K ` W W a

( , , )
K ^ S W S [ K

(
P R

)
m V

Fig. 13b
n [ K N Q Q K ` N R

C 6 5 @

>

>

y
^ T

>

>

z
S o

>

>

* j

N R S

K ^ S W

(
P Q Q S

)
u

(
m j P R

)
V

Fig. 13c
j W X Q P R K N W a

8 5 @

>

>

y
r R

>

>

z
N ` K

>

>

R V

X Q P

( , , )
Q Q K ` N R V N ^ K

(
m j P R

)
]

Miller Index Nomenclature:

g o ` N S S K R T R S T X T U S [ K R M ] K ` P R g X P N ` T U W L M P ` K ` P ^ s K S W . g

0 i w w

W i y

. i w w

. w w i

Fig. 13a
b ` P ^ s K S W R V N ^ P S K P

m |

3 i w w

T i w w

j w w i

Fig. 13a Introduction.

Y t | W i w U T ` P ] T ` X [ g [ P O K K ^ T ] K W S ` P

g f

m f

m h

Theory.
` K W K P ` ^ [ K ` W g K Q T o o [ N ^

dc

E Kc A H H
V V V V V V V V V V

dc = A= E= Kc = H=
Y H G G N O M R H L J U

Table 5
I N M L U J h

Table 5. Selected Properties of Some Brittle Materials

~  ~

A
Y Q P I

Equation (12) Kc
] P G H I J K L \ P Q Z N Q L R T I J H

E
] R K P Q

H
K H G I

L G Z U Y J Y

] J K G P I G K F

P \ P H

Y K Q J Y P j

Kc E
] ] \ H L Y K Q Z P F J Y N \ [ m m

H
^ S J Y P U J L Y H

\ h N N G S P

K \ P

J U R P N

K H J

Microcutting Tools
g G K y P Z P L H U I P H Q P S H g P G N O J Y P J N N G H Q Z I U

Example 10, Mirror-finish Micromachining:

P R I

f I O

Case Study.
q \ H G G S R N N P k L U J J N I J U Z T J Y P Z

Fig. 14
^ I ] | u } R H x L N \ F G P J

g f

g f

\ Z I U P P Q l

\ Z J Y P N G P Z

\ P F J Y N J P R K H G

Figs. 15 16a
] ]

16b
^

Cutting Fluids in Micromachining

K L R N \ K G G K Q S H Q Z \ K L R N Z R K G G K Q S ] H \ N Q S J Y P \ N I J P R I H J K G P \ H Q U M H L J U R K Q S F R N L P I I P I ] L H Q k g P G P P R H S P Z M R N \ P i K I J K Q S J P L Y Q N G N S T J N F R N Z U L P t \ K L R N F H R J I N R \ K L R N L H K J K P I K Q \ N G Z I

g j

g f

Safety.
Q N J N Q G T L Q H J P I N J Y P

Benefits.
S R K Q Z K Q S L H Q J K N Q N M \ K L R N

g f

g f

g j

Courtesy of Unist Inc.

g G U R K L H J K N Q \ H L Y K Q K Q S H R P g g R P I P N K R M N R K N L N \ F H J K G P k

g f

Fig. 17
^ J \ K i P I H R P L J J Y P \

g j

Selection of Cutting Fluid.

F U R F N I P I K Q \ K L R N \ H L Y K Q K Q S h L Y P \ K L H G G T H J Y K S Y J P \ F P R H J U R P

Pendant drop technique:

g j N M H I N G K Z J U P h Y P I K Z P K P k U I K Q S H J P Q I K N \ P J P R [

Figs. 18a

18b
^

? =

>

<

<

4 7

     + #      ,   $  % #    #           +  . #   "  #     "  % #        %   /

   $ #   #            "

    #       % "   %   /    % #        

Sessile drop technique:

N M J Y P Z R N F K I H Q H G T y P Z J N L [

Fig. 19
^

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&

&

&

&

&

&

&

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&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

Drop Size Measurement.

g J Y P & U Q Z H R T H K R G H T P R \ & K Q k O H R Z h ) H G L U G H J K & Q & M \ & \ P Q

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

'

&

&

&

&

&

&

Table 6
& ' & & & &

'

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

'

&

'

&

&

&

'

&

&

&

&

&

&

&

&

Table 6. Liquid Droplet Measurement Techniques

  " ,    " ,

Slide:
  

Light shadowing:
      

Solidification:
,   $ #

Laser Doppler Anemometry:

   #    #  % #  %   / # / # # /  

Momentum: Heat Transfer:

 $   #  

Laser Diffractometry:
  "   %      & '

&

&

Fig. 20a
& & &

&

&

&

&

&

&

&

&

#  "  %   /              #  %       /  

&

&

&

&

&

&

&

&

&

&

&

&

'

&

Equations (13)
&

(14)

&

&

&

&

&

&

&

&

&

&

&

V D

h h

P h

V
&

h h

P h

V= P= h= D=

&

&

&

&

&

&

&

&

&

&

&

&

&

'

&

&

&

&

&

'

&

&

&

&

&

'

Table 7
)

&

&

'

&

&

&

&

&

&

&

Table 7. Properties of Selected Lubricants

"   #  "  % #    / /

     # /  

   #  #   # 

.   #   # 

.   #   #  .

Example 11, Drop Size Calculation:

          

# & '

$ )

Equation (13)
+ "

h h
" " " " " " " " " " " ! #

"

P h
" " " " "

(
" " " " " " "

"

"

"

"

"

"

"

"

"

"

)
( " " " " " " " " " " " " 

&

'

" " " " " " " " " #

"

"

"

"

"

"

"

"

"

"

"

"

"

( )
! ( " " " " " " " " " " " " " " " " " " " " " " " # & ' (  

&

'

Equation (14)

V
" " " " " " " ,

" " " " " " " " ,

&

'

" " " " " " " "

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

&

+ -

&

'

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

'

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

Contact Angle Measurement.

& &

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

P V

(
0

K
&

&

)
&

P= V= = K=

&

&

&

&

&

&

&

<

>

<

&

&

V
&

normalized diameter
& &

&

&

&

'

Table 8

Figs. 22a
& & & &

Equation (15) 22b

&

&

Fig. 21
& &

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

D E

&

&

&

&

&

&

&

&

&

&

&

&

H H I J % % % K I H . L H H I L M J I

H # I H . J I H # I H K J N J L / O P

Table 7
& ) & R

Fig. 23

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

&

< >

, I

# J H J % U J I H # U H # I I J K / # M J H J % U J I H # U H # I I J K / # M

, K # # I M K # I J % U J I H # U H # I % J K M % % K I H U L H H I % L M

J I

H # I H H L I H I U # K

M # I M H H # I L /

Table 8. Contact Angle () of Micromist Droplets for Practical Tests

Machinery's Handbook 29th Edition

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Example 12, Contact Angle Measurement:

8 4 : 7 % 2 : % : % ' % 6 3 ) 8 6 ( 7 ) % & : ( ; < 1 / = > ? ( 2 3 5 ) % & : D + % 3 : * 6 % 8 ( 2 3 & ( ( ) + 3 E % 6 F : + 4 5 6 ( : 5 ( 7 % D 4

&

'

V
4 * + +

. @ ; 4

&

&

&

&

&

&

'

&

P
% 4 & : + +

&

&

&

&

&

&

&

&

&

&

&

&

Graphical Solution:

&

&

P
          

V
$ & 3 6 & 4 2 A 3 & 7 ( 4 2 & N , O . ( 2 & 9 % ' %

} ~

(
5 3 ) P ( 6 + 3 ) 4 B

)
% 8

} ~

&

&

PV
2 & 3 5

Fig. 22b
4 : 3 & < . Y

&

&

&

&

&

&

&

'

&

'

&

&

&

&

&

&

&

&

<

&

&

&

&

&

&

&

Table Look-up Solution:

1 ( 5 3 & % 7 6 ( ] % 5 & % 8 8 6 ( 7 : 4 B 5 9 ( ( : % & 9 % 5 ) ( : % : & 2 * + H % 6 D

&

'

) * +

&

&

Table 8
4 : 2 ( & 3 '

&

&

&

&

&

&

&

&

Example 13, Contact Angle Measurement (continued from Example 11):

8 6 ( 7 ) % & : ( ; < 1 / = > ? G % 6 % 5 ( ) ) % 5 & % 8 ( 2 3 A ) 3 : : 7 ) 3 & % D & 9 % 3 ' % 6 3 A % 7 6 ( ] % 5 & % 8 G 3 : + % 3 : * 6 % 8 D 3 2 8 & 9 % 3 ' % 6 3 A % 8 6 ( 7 ' ( ) * + % G 3 : 5 3 ) 5 * ) 3 & % 8 & ( H %

Example 11 P
D ( 7 : 4 B % , / @ 9 % 4 2 ; ( 6 + 3 & 4 (

&

&

&

&

&

&

P
          

                                   

V
J H V : %

} ~

(
3 + % & % 6

; / . 0

)
^ D

} ~

Fig. 22b
+ % 5 * & & 4 2 9 4 : 4 : 8 * %

&

&

&

&

<

>

&

&

&

&

&

&

&

&

&

&

Dynamics of Microdroplets.
 
 
           
   
              
 
     

Propelling Microdroplets Toward a Rotating Tool:

  
        " "            
 
        

x pn y pn

Vf t

(V m

Vf ) (

t m)

V m

t m)

xpn, ypn = = D D, m = t= Vf = V =
  
                         

"

"

"

"

ypn t
 !     

"

"

mV
!         

  

"

"

Force Balancing of Microdroplets on a Rotating Tool:

 
 
      
                            
      
       
     
               

Wa
 

S
    

L SL

      

) L

L = S = SL = Wa =

Equation (18b)
  
     

"

m ( Vc ) P( Dt
    
    

) L
!

L = = m= Vc = P= Dt =

"

Fig. 25

             

"

    

"

y e e

h m v i b q g n s

y p p n q j g s l r q g i v b r l s j j m g s r b o o l i l n s t k l l r t d

y k p k b q j p l s l i

Note:
                         
      

               

 

Fig. 26a
             

"

Fig.

26b

&

3 . 4 5 % 4 % .

&

'

&

&

z a b c d e g d j p k s g s b j n g m o m b r r n g p b q t b p m g s b j n j o p b q i j r i j k m l s r n g p b q t d

J S

<

>

<

<

>

<

J S

<

>

z a b c d e v d h i g q s b q g m p g q w b n b n c t l s k t j o s j j m g n r u j i k b l q l s j g j b r t s g c n g n s j n l d

Case Studies.
            

Use of Micromist in Micromilling of 316L Stainless Steel:

                     #          
                     
                 

Tool Life
 
   

Fig. 27

Fig. 27
   

  

  
 
 

Fig. 28a
!    
 
     

Fig. 28b
!       

q p

| a b c d e d

o o l q s j o q s s b n c o m b r q j n r b s b j n t j n p b q i j p b m m b n c j o
]

z t s g b n m l t t t s l l m d

d
]

y d
_

x a b c d e
_

{ m j u l i i b c w s g n r g r w l t b j n a b c d e
_

x u l g i k k l i m l o s

{ j n g q g i v b r l s j j m d u l g i j n g q g i v b r l s j j m d

x r i q s s b n c

y d f p b n
i

y
_

{ p
^

x p b q i j p b t s e

y d

| p b n
i

y p
^

{ p b n

y
k

y p p

d
]

Use of Micromist in Macrofacing of 4140 Steel:

   
     !     
                 
    
! 

Fig. 29
       
   

Figs. 30a
           
 

30b
          

30c

 
 


'

& N O P N

K #

"

<

>

>

Comparison of Tool Wear After 75 Facing Passes

b c c

Microfabrication Processes and Parameters

Micromilling.

Table 9

Microcutting Tools

Tool Sharpness



Figs. 26a 26b 31a

31b


Fig. 32


Positioning of a Micromist Nozzle in Micromilling

"

"

Table 9. Commercial Micromills

H I J K L M N O L K

K P Q

N P

K P Q

)
+ * W 4 ( + / . ' . 0

'

'

'

'

'

'

'

'

&

'

'

'

'

'

'

&

'

'

'

<

>

'

'

&

'

'

'

'

"

"

Microdrilling.
S P Q b c R S _ T

] T

S T

S P Q

] ^ T

O ^ _

K ` _

S P

] ^ _

K T

L T P

S P Q T ^

O ^

N P

L _ _

S P Q

M T g

K P

S ^

] T

S T

S P Q

K ` T

O ^

S ^

J _

L T P

S ^

] T

S T

O b

O ^

S T

O b

S ^

] T ^

O g

M T

S ^

] T

S T

S P

N T

N T ^

S P

S Q T

J P g

L P

K P

J ^

S P Q

S Q

Tool Sharpness
S T ] S K e g

L p

e b q _

S P

L T P

K g

K P

f P

S P

N P Q

S ^

] T

S T

S P

N P Q

K T _

L T

] b P

K T

S T

S P

] _ T

S P _ T

S T

S P Q

K P

R T

M P

K T

K g T

S T

L T

L ^

L Q T P

K ^

S P

S ^

S P

S P

J P

K T

S P Q P

S P T T

L Q

J T

L T

S Q

J _

K T

S b s

S P Q

K P

N T ^

] T

S T

S P Q

S P

S _

] T

] P

S P Q

L ^

K _

K P

K T

S P

J ^

S P

] T

R b

] _

S P Q

M P

S _ P

S Q P P

S P Q g

K ^

L T

S P

S P Q

K _

S P P

O _

S P Q

K _

] s

K ^

L T

e T

K k b v

a ^

K T

K _

N j k

K ^

S P Q

K _

] P

M P

N T w

P D P D
a a a a a a O _

(
b v

N T

R R>

H j l n

N k T

S P

] T

K ^

S P Q

K _

H ^ ^ g

S P n

P= D= R= Example 14
P

H T ^ ^ g

S P n

K T

K _

S T

K ^

N T ^ T

K P

Equation (19)
K K R

I _ _

e ^

] T ^

S `

r P

S _ P

S P Q

S T

S _ z ^

S P Q

O P

{ k

f | k }

S `

J T

] ^ ^

H P

e g

S _

f P

Fig. 34
n O S J T

] T

S P Q

K P

S ^

] T

S T

M T

N T

a T

K P

S T P Q

S P

L p

K P

S P

N P

S T P Q

L T

S T

S P

S P Q

N ^

] T ^

K b

'

'

&

'

'

] c ^ ^

O ^

] T

S T

S T

N T

S T

K ^

J T

N j k k

H k b k k m

S P

R n

Table 10
n

>

'

"

"

Table 10. Commercial Microdrills

'

'

'

'

'

'

'

'

'

&

'

'

'

'

'

'

'

<

>

'

'

'

'

Example 14:

Table 10

Example 2

Table 11

Equation

(19)

"

"

Table 11. Pecking Cycle, Drill Dia. D = 0.005 inch

 . 2 W ( * B ) , . 4 . & '

&

'

&

'

'

PD

P
: G : G

Microturning.
S

L s T

K ^

S P

L T

S P

K P

N ^

L T

K T

] _ T

S P _ T

S T

K _ ^

N ^

] T

y P

K P

L T P

S P Q b

R P

O Q

e _ T

J _

S Q

R p

J _

S T

J P

R _

S T

O _

K T

N T ^ ^

J g

S T

J g

S ^

] P

K T

J g

e ^

J T

K P P

] P ^

e _ T

K T

S P

O Q T

S P

S P Q g

S _ _ P Q g T

O _

S P Q _ T

J b

] T

y P

K P

L T P

S P Q

J _ T

S P

K T

J _

f T P

L T

M ^

K _

K T

S P

a T

S Q ^

H ^

Ductile Regime MicroJ K

machining
S

J ^ P

] T

O ^ ^ P

N T ^

] T

y P

K P

L T P

S P Q b s

] T

S P

H ^ P

J T

S P

N T

S T ^ ^

] T

S ^ P

J P b s c

O T

J ` _

S ^

M _

S T Q

L P

K T

O n

K T

K P Q

K T

S P

S T b q P Q

] T

S P

H ^ P

K q c n

M T

N T

S ^

] T

y P

K P

L T P

S P Q

e w

S P Q

] T

S P

K T

L T

] T _

S P Q

J Q

J ^

J j k P ^ g

S Q

O T ^

] P

O ^ P Q

S P Q P

S T P Q ^

S T

J g

S P

S Q

K T

K P Q

R P

J T

S Q

K ^ _

L T

S Q

J P

L T ^

K T

K _

N T ^

S P g

K P

N T

S P b

K ^ P

O g

S T g

M P

S T

I b

K T T P

t T

O P Q

S n

S ^ _ T

J Q

K T

K P Q

R g

H P

S n

N T ^

J T

] ^ _ T

K T

S P

K ^

S T

S P

N T P

M P

O g

K P

N T

S T

S P ^

] T

S P

S P b q

S P

O Q

] T

K ^ P

e _

H j j k n

] T

O _

J P

t T

M P

r T

K P

t P

K T

J _

J P

J b

e P ^

S T

M P

e ^

] T

y P

K P

L T P

K ^ P

O b

L T T

J P

] P

M T

H q

S c n

K T

N T

K ^ P

L T P

S P Q

S P

N T ^

S Q

] P

K P T

M T P

S P

K ^ P

] T P

K P T

S P

r P

M T P

S P

f T

t _

K ^

S T

J b

K T ^

S T

J g

L Q

R ^

S P

R ^ Q

L P

] P

K P

S P

N P

S ^ _

L T

J b

I P

S T

] P

S P

J ^

S Q

S T _

M ^ P

N T

J P

S ^

J P

] ^

S P

L T

M T

e T

S P

e T

L ^

] _ _

I T c j |

K _

J P

S ^

Fig. 36a
N S P S J R J L T N

Fig. 36b
n 3 2 ' ) 0

Table 12. Examples of Diamond Machinable Materials

.

'

'

'

&

&

&

'

'

&

'

>

'

'

'

'

'

'

'

'

&

'

&

"

"

] T ^

J T

L p

S T

M T

] P

K P

] ^

S P

L T

R b

S ^

] T ^

K P

f ^

S P Q

S ^

] T

y P

] P

S _

N T ^

] ^

S P

L T

I b

L p

K P

S P

N P

S T P Q

N ^

] T ^

L T

S T

S P T P ^

K P

J b

6 ( G A Y 7 G . . & 1 2 0 + ' 2

1 3 0 ? + 2 .

&

'

'

'

&

&

'

'

'

'

] T ^

S P

S P Q

S P Q P

S T P Q ^

S T

J g

K ^

S T

O Q T

S P

Speeds and Feeds.

e

J ^

] ^ _

K T

S P Q

S ^

J P

S P

S P

J b P

t ^

S T

K _ T _

J ^

S T

K T

K P Q

R g

J T

J g

K P

O T ^

] P

K ^

S P

S P Q

N _

] T ^

K P

f T

t _

S Q T

J P

S ^

K T

S Q

K P

f T

t _

K ^

S T

S ^ T

N P

] P

S P ^

] T ^

S P

S P Q _

N T T ^

] P

S n b q P

O _

N T ^

K ^

S T

a T

Workpiece Materials
O O e R

K T

K P

S T Q

S P

O ^

S T

O g ^

S P

S P Q

L ^

S n

K _

K P

a T

H T g

S n

S Q

Microcutting Tools

Example 15, Work Hardening of Titanium Alloy:

S T

N T

S P Q

L T P

S P Q

J _

N P

K T

Microturning Parameters:
J L T N

S P

R g

O P

] P

K T P P

N T

L T

S P

L T P

S P Q

J T

S P

S Q

L b c

S P Q

J _

N T

S P Q

] T

S P

e ^ P

S Q

J P

e P

S T Q

L _

K P

] ^

S P

M _

e b

L T P

S P Q

K j k k

a v k k ^

y ^

S P

H k

a j

{ v k

y ^

S P n

] ^ ^ P

N T ^

K ^

K P

K ^

S T `

] ^ _

J b

O q

S P

J _

K P

L T

S P

R T

L p

S T

M g

S ^

M P

N T

S P Q

N ^ P

K T

L T P

S P Q

S P

S T

O ^

N T

] ^

a T ^

S P

L T

S P

J P _ T _

L ^

K _

K P

O P

S T

K ^ T

] P

S P Q

S Q

J g

S T

J P

L _

K Q

O g

N T

N T

S P Q

J _

J P

O Q

S Q

t T _

N _

] T

S P

K ^

S T

S P

S Q T

J P

S P

S P T

K P

S P

K P

S Q P

K P

L T

S P

J T Q

R c

S _

] T

O ^ _

e T

f ^

L T T g

S P

K T

N T ^

S ^ _

N T

K ^

S P

S P

K ^

e P

R T P

J _

S P

K T T T ^

S P n b

K T

L T

S P

N T

L P

S P

K P

O P

S T

J g

] P

M P

] ^ _

N T ^

S P

Equations (20)

(21)

Figs. 37a

37b

Rt Ra
    

f
s r / = / /

r w

R R
s v v

f R
r / / / / / / / t  /

f R
r / / /

k ( f, R )
 % ' ( ' #  ) &

f R
r / / / * + ' % ' ( ' #

f R
r / / / ,

f < R
/ /

Ra = Rt = f= R=

"

&

'

&

&

'

'

&

&

'

'

&

Example 16, Turning Parameter Selection:

Solution:

Depth of cut: Cutting speed: Feed:

Fig. 37b

R
T

Equation (21)

Ra R
/ / / / / / / / / / / / / / v / / / v / / / / / B B u u 7 E

/ / / / / / / u

/ / / / / / / / / / v / B u 7 E

/ v

/ / / /

/ /

>

Effect of Tool Nose Radius and Tool Feed on Surface Finish

z ~ 

Microdrilling/Milling Parameters:
%   ( 4  %  ( 4 6   ' ( ' 1 & & 2 & 0 . 0 1 1 2 7 8    ' '   ' #   ; $ ( ' ( 6     0 & 0 & 2 0 & 0 1 0 =

'

'

'

'

'

&

&

"

'

'

'

&

'

'

'

'

'

&

&

&

&

<

"

'

>

"

"

&

'

'

'

'

'

'

'

'

'

&

&

&

&

&

'

'

Fig. 38
' ( B " E G H 4 ' *    0

'

'

'

'

&

&

&

&

&

&

'

'

'

'

&

&

'

'

'

'

'

'

&

'

'

'

'

'

'

"

"

&

'

'

'

'

'

"

&

'

&

&

<

>

<

>

"

&

'

O f a \ W k d ^ f f f a ^ ^ d
   

L a b b d

M i d g a ^ f


f z y ~ 

\ ~ { | {  y z

` h f f

M V W X Y


Tables 13a
* '  * ' ' ( & 1 2 2 "

13b
4 * ' & (  * 1

'

'

'

'

"

&

&

"

&

'

'

'

'

'

'

"

<

&

&

&

'

'

'

'

'

'

"

&

"

'

'

'

'

'

'

'

'

'

'

'

"

&

&

&

&

&

"

Fig.

40
,

Example 17, Micromill and Microdrill Selection:



Micromilling:

Table 13b

Fig. 38

Microdrilling: Table 13b

Table 13b

Table 13a. Speeds and Feeds for Micro Milling/Drilling with Uncoated Carbide Tools

D D

Table 13b. Speeds and Feeds for Micro Milling/Drilling with Uncoated Carbide Tools
  

D D

MACHINING ECONOMETRICS
Tool Wear And Tool Life Relationships Tool Wear.
 

"

"

&

'

'

"

'

&

"

'

"

&

'

'

'

&

"

"

&

"

'

&

"

"

&

&

&

'

&

"

"

'

&

"

'

Fig. 1


&

'

"

'

'

&

&

&

"

"

&

"

&

'

"

&

"

'

&

"

'

'

&

'

&

'

&

"

'

'

Fig. 1

Average

Wear, mm

0.1

Low Average High

0.01 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Cutting Time, minutes

: ; < = > = : ? @ A B C D @ E @ F @ : G A H I ; J A J K L G I I ; A < M ; N D

"

"

Fig. 1
 $ &

'

P  #

"

&

"

&

"

"

"

'

"

'

"

&

'

"

"

'

'

Equivalent Chip Thickness (ECT). ECT

      # &

"

"

"

&

&

&

"

'

"

&

ECT
#

ECT


&

&

'

&

"

"

&

"

"

'

&

"

"

&

&

&

&

'

ECT
( 

"

"

&

"

"

"

"

&

"

"

&

"

ECT


&

&

"

'

&

"

"

&

'

ECT


'

"

&

"

'

&

&

ECT


&

"

&

&

&

"

"

ECT

"

'

&

"

"

&

&

&

"

"

ECT

ECT
  ' $

Area CEL
! ! ! ! ! ! ! ! ! ! ! !

A=

"

&

&

"

&

"

CEL =

Fig. 1

&

"

A


&

"

ECT

CEL


ECT

'

'

"

"

"

Example 1: CEL
^ 5

"

"

&

"

&

ECT ECT CEL MRR

 

"

&

&

"

&

ECT V

"

"

"

&

&

MRR
  

V Area


V ECT CEL

V Area
 

&

"

SMRR

&

CEL
(

SMRR

V ECT


V ECT
#

Example 2:
 

&

"

V
`

&

"

SMRR
%

ECT in Grinding:
  .

&

&

ECT ECT Vw ar V
  #

"

&

'

Vw


'

&

ar

&

"

A Vw ar V
^

"

'

&

ar
( 

'

&

Vw,


"

"

'

'

"

&

"

SMRR


Vw ar
 

ECT
2 X

&

"

&

&

&

GRINDING FEEDS AND SPEEDS

  Y

&

1197
  #

Tool-life Relationships.
  '

&

"

&

'

&

"

&

Fig. 3
P

"

&

&

'

'

40

40 VB = 0.15 mm VB = 0.2 mm VB = 0.1 mm VB = 0.05 mm

30

30

LF (tool life travel ), mm

LF (tool life travel ), mm

VB 0.05 mm VB 0.1 mm VB 0.15 mm

20

20

10

10

0 0 0.05 0.1 0.15 0.2

0 200 250 300 350 400 450 500

Fz (feed per tooth), mm

: ; < = i = j A K ? G D A H D J K K D D k l D E I J J I m J A H G I I ; A < I ; N D : ; < = n = j A K ? G D A H D

VC (cutting speed), m/min

J K H G I I ; A < F l D D k J A I J J ? o ? ; K D

"

&

"

"

&

&

&

'

"

Figs. 2

4
(

'

&

"

"

'

"

&

&

&

Figs. 6a 6b Taylors Equation. T



6c

&

'

"

&

&

"

"

&

"

&

V Tn
  ' $

n=

&

"

&

"

T
 $ 

"

'

&

n
8 &

&

"

"

'

"

"

"

"

V n ECT
t (

T
!

&

"

Equation (1a)
 

"

&

&

'

&

'

"

"

&

'

&

ECT n
)  &

Fig. 4


"

T
( 2 )  "

&

V,

&

"

"

"

ECT


Fig. 4
( 

"

TV
! 

"

"

"

&

"

"

'

&

Figs.


2


&

&

&

'

T


&

"

"

&

&

"

"

"

&

"

"

"

"

'

&

"

&

"

"

&

&

"

"

"

"

&

"

"

"

100

Tmax

ECT = 0.1 ECT = 0.25 ECT = 0.5 ECT = 0.7

T2,V2
T minutes
b 10

n = a/b
a

T1,V1

1 10 100

1000

V m/min

Evaluation of Slope n, and Constant C.

n T

V1 T1n V2 T2n

V1 T1 n

V2 T 2

(V V ) (T T )

Example:

Fig. 4

ECT

ECT

T2

V1

V2

T1 V1

T 2 V2

V Tn

The Generalized Taylor Equation.

LA

Tn

A f m a p LA q r s

A=

n, m, p, q,

s=

n m p q s

Equation (2)

f a LA

r,

The Generalized Taylor Equation using Equivalent Chip Thickness (ECT): f a LA r ECT Equation (2)

V Tn A ECT m Equation (3)

V ECT

Equation

(3) The Colding Tool-life Relationship. N0

H K L M

ECT

(4a)

(4b)

VT

(N

ECT )

ECT

H M

ECT M

H M

x= M=

ECT y =

V z=

x H M T

z(N

Lx )

VG

2M = K=

ECTG VG ECTH V

ECTH VH Fig. 5 V ECTG ECTH VH

N0

L=

ECTH K VH n ECT n N0 L

ECT

1000
VH

H-CURVE K = ln(VH) M G-CURVE

VG

2M

V, m/min

100

Constants N0 and L define the change in the Taylor slope, n, with ECT

T=1 T = 100 T = 300

H = ln(ECTH)
ECTH 0.1

10 0.01

ECTG

ECT, mm

H K L M

N0

N0

n1

n2

ECT

ECT H K M L N0

V ECT

The G- and H-curves. MRR

 
                   

G
    

SMRR
   

TO is Constant
              

TE Optimization Models, Economic Tool-life when Feed

                     

1149
  

TV
       

ECT
     

T ECT
         

V
 

V ECT
       

T
   

V ECT
     

Figs. 6a 6b
    

6c

"

100

T minutes

10

ECT = 0.1 ECT = 0.25 ECT = 0.5 ECT = 0.7

1 10 100 1000

V m/min
# $ % & ' ( & ) * * + , + $ . / 0 & 1 2 3 3 $ 4 % 0 5 . 6

T V ECT
, 7      

Fig. 6a
    
   

Fig. 6b
           

ECT
      

H
 

ECT
10000

Fig. 6c H G
   

Fig. 6c

1000

V = 100 V = 150 V = 225 V = 250 V = 300

T minutes

100

10

H-CURVE

1 0.01

0.1

ECT, mm
# $ % & ' 8 & ) * * + , + $ . / 0 &

ECT T ECT
, 7       

H
 

ECT
  

<

<

<

<

>

1000

H-CURVE G-CURVE

V, m/min

100
T=1 T=5 T = 15 T = 30 T = 60 T = 100 T = 300

10 0.01

0.1

ECT, mm
# $ % & ' 1 & A 2 3 3 $ 4 % 0 5 . . 6 / 0 &

ECT V ECT
, 7

The V-ECT-T Graph and the Tool-life Envelope. V ECT T G

  
                     
           F   G   9   
   B C        B          
       D E       :       

Fig. 7
   9    

TMIN
     

TMAX
      

<

<

TMIN
     
  I

TMAX
      

ECT
      

<

<

<

<

<

<

V ECT T
         

V ECT
      K :      

G
    

ECTMAX
     

1000

V, m/min

T=1 T=5 T = 15 T = 30 T = 60 T = 100 T = 300

H-curve A' A OF

Big Radius To Avoid Breakage G-curve

Tool Breaks

B E' 100 0.01 E Tmax 0.1 OR D C 1

ECT, mm
# $ % & M & A 2 3 3 $ 4 % 0 5 . . 6 / 0 &

ECT V ECT
, 7     

ECT
        

ECTMIN
     
    

H ECT
  

"

"

ECT

Fig. 7
q s j m a j k r c ^ m b t

u i b _ _ b a b

ECTMIN
b r ` a ^ j x j w r ` l ^ ` c l b y a i j w s k a

ar D
q ` m l s k a a b r l ^ ` r f z j r h _ ` c c x r ` a ^ j h a i b s i ^ y a i ^ s { m b h h n b s j _ b h h j h _ ` c c a i ` a ^ a

ar
q ^ h

D
m b s b h h ` r d a j s j _ y b m h ` a b n d ^ m s r b h a ` r a ^ m v j m y ` v b w j r

ar D
` h ^ m v a i b w b _ j r b j m a i

High-speed Machining Econo^ h a j y ^ s f

metrics Fig. 7
w j r w ^ m ^ h a i b h y b b

1161
l b _ j m h a r ` a b h ^ m y r ^ m s ^ y c b _ ^ m ^ _ k _ s j h a s j m l ^ a ^ j m h w j r r j k v i ^ m v ` a y j ^ m a q q

OR
q ^ m a ` ^ m e e _

OF
q _ x _ ^ l ` w k

OR
q e f h a ` r a ^ q

ECT
| ^ _ ^ c ` r c d o ^ c c n b r b ` s i b l

a u

V ECT
h j s s k e e q

ECT T
q ^ m a u f q

T
f j e

H
j j c c ^ w b o ^ c c

ECT
` m  a ^ m k ^ m v a

a u

a u

ECT OF V ECT T ECT V ECT ECT T ECT

g e f e q  ` a e f e g f e e q e f e q ^ m a t e f e g l o ^ a i a i b s k a a ^ m v

T
m

H
j a i b c b w a c ^ w b o ^ c c l b s r b ` h b ` m l h b r ^ q

T
a ^ m k ^ m b r b

H
a j a i b c b w a c ^ w b o ^ c c l b s r b ` h b ` m l h b r ^ j k h q _ ^ m k a b f 

T
i b r b ` r v b o ^ a i ^ a h

Cutting Forces and Chip Flow Angle. 8 LA f

a i ` a ` r b ` h h j s ^ ` a b b l q ` m l w b b l y b r r b } j c k a ^ j m j r ^ m _ ^ c c ^ m v w q q ^ m v ` m l j m b w j r w ^ m ^ h i ^ m v j y b r ` a ^ j m h f

Fig.
w s k a c b ` l ` m v c b

r
q b b l y b r a j j a i f i b r b ^ h j m b l r ` o ^ m

a
q v w j r r j k v i

fz

Roughing:
a r (1 sin (LA)) feed x r f -2 S r(1 sin(LA)) a O CEL LA(U.S.) LA(U.S.) z = 90 CFA f b = --- + r cos (LA) + 2 tan (LA)(a r sin(LA)) b FR FH
FA

Finishing:
ECT a < r (1 sin(LA)) c f/ 2 u r CFA ra u= 90 CFA s x ax

ax

CFA

a ---x CFA = 90 atan ----b FR Axial Force = FA = FH cos(CFA) Radial Force = FR = FH sin(CFA)

FH
FA

f2 --x = r r2 4 f -- + r (r a)2 c=2 a---x CFA = 90 atan ---c ISO LA = 90 LA (U.S.)

ECT
m l ^ s ^ ` c w j

CFA
c ` m b f o ` r l

FC
q j w j r s b h ` r b a i b w b b l j r ` ^ ` c w j r s b ` m

FA
q y ^ b s b f i b r b h k c a ` m a j w ` m l ^ h s ` c c b l f i b m w ^ m ^ h i ^ m

FA
i ^ m v ^ h k h k ` c c d n ^ v v

FR
b r a i ` m f

FH
i b l ^ r b s a ^ j m j w

FR FR
v q _ b ` q s k a a ^ m b s a ^ j m

FA
q h k r b l n d a i b s i ^ y w c j o v b l v b c b m v a i ` m l ` c ` r b ` j w s k a

FA
` m v c b ^ h y b r y b m l ^ s k c ` r a j a i b r b s

FR
a ` m s a j w ` m l u s j m h

FH
v c b w j r _ b l n d a i b a ^ a k a b h a i b s r j h h h q

CFA
q a i b y r j l k

ECT
^ _ y j r a ` m a a ` h { j w l b a b r ^ m a i b w j r _ k c ` h v ^ } b m ^

ECT
_ ^ m ^ m v a i b m a i b

CEL A
f r b h i j

FH
q f

FA
` m l ^ h l b h s r ^ n b l q q

FR
q ^ m a i b w j c c j o

Fig. 8
i b _ b a i j l w j r s ` c s k c ` a ^ m v a i b _ ` v m ^ a k l b h j w

FH FA
v f i b w ^ r h a a i ^ m v ^ h a j l b a b r _ ^ m b a i b } ` c k b j w a i b s k a a ^ m v w j r s

FR
b f t y y r j ^ _ ` a b w j r _ k c ` h

FC

ESTIMATING SPEEDS AND MACHINING POWER Specific Cutting Force, Kc: FC Kc FC A Kc ECT Kc ECT Kc B Kc Kc ECT B
i b h y b s ^ w ^ s s k a a ^ m v w j r s b j r a i b h y b q b w ^ m b l ` h a i b r ` a ^ j n b a o b b m a i b s k a a ^ m v w j r s b ` m l a i b s i ^ y s r j h x _ _ f i b } ` c k b j w l b s r b ` h b h o i b m ^ m s r b ` h b h ` m l o i b m a i b s q h k ` c c d ^ h o r ^ a a b m ^ m a b r _ h j w ^ a h } ` c k b ` a s ` c c b l q  q q w s k a a ^ m v h y b b l a i k h o i b r b h c j y b ^ m c j v c j q q

1081 Kc A
a q q f a i k s r b ` h b

V
` m l m b v c b s a ^ m v a i b b w w b s a v s j j r l ^ m ` a b h

10000 V = 300 V = 250 V = 200

Kc N/mm2
1000 0.01 0.1 1

ECT, mm

Kc
^ c c k a i b q

ECT
r ` a b l j l `

Fig. 9
q l ^ w w b r b m a s k a a ^ m v h y b b l h f p m a o h i b l c ^ m b h r b y r b h b

Kc
m a a i b ` w j r b _ b m a ^ j m l c b } ` c k b j w s k a a ^ m v h y b b l q ^ m s r b ` h b h w r j _ e f a j e f _

ECT
b l b k ` } ` r ^ b h

Fig. 9
a ^ j m o i ^ s i b ` s i i ` } b l ^ w w b r b m a h c j y b h f z j r a i b _ ^ l q q

B
_ o i b m

Kc
_ f b m i b m k h ^ m v

ECT
b r ` c c d a i b h y b b l b w w b s a b s j m j _ ^ s h y b b l h f

ECT
k l b j w ^ h ` y y r j ^ _ ` a b c d a j y b

Kc
1

FH/FC

V=300

V=250
V=200

0.1 0.01

0.1

ECT, mm

FH FC
k c ` a ^ m v

ECT
` m l

Determination of Axial, FA, and Radial, FR, Forces: FH FA FR

h k c a ` m a w j r s b ` m l a i b m s ` c s k h ^ m

Fig. 8

FH

FH FC
q h i j o h i j o a i ^ h r b c ` a ^ j m h i ^ y _ ` d } ` r d f t h h b b m ^ m x ^ h ^ m a i b r ` m v b

ECT
e f g a j e f o i b m } ` r ^ b h w r j _ e f a j

Kc Fig. 10
_ _ ` m l

Fig. 10 FH FC
q h y b b l } ` r ^ b h w r j _ e e a j e _ x _ ^ m k h ^ m v _ j l b r m ^ m h b r a r b ` h j m ` n c b c ` r v b w b b l h x ^ h ` r j k m l e f g e f ` m l o i b m

ECT
l b h ^ v m h ` m l v r ` l b h w ^ m ^ h i ^ m v ` n j k a e f

FH FC
b a b r _ ^ m b ` m l n ` h b l j m a i b s i ^ y w c j o ` m v c b ` m l a i b

Example:
^ m a k r m ^ m

FA
v f c k b j w e e

FR
q x _ _ w j r r j k v i ^ m v o i b m q

CFA
e f ` m l a i b s k a a ^ m v b l v b

FC
q h ^ m v ` } `

Kc
m v a i _ _ w ^ r h v w j r

ECT
_ _ f i b y r j ^ _ ` a b } ` c k b

CEL FC
s b b o a j m ` } ` c k

j w

A
e e g e e e b o a j m ` m l ` m ` y q

FH
w ^ m ^ h i ^ m v o i b m e f ` m l a i b s k q

a a ^ m

Kc
m v a i _ _ s ` c s

ECT
e f _ _ f i b s e f g

CEL
e e e b  s ` m n b

A
` m l ` m ` y y r j ^ _ ` a b } ` c k a j b h a ^ _ ` a b w j r r j k v

b j w i ` m

FH
k h b l l w ^ m ^ h i a

k r m h a ^ _

FC
e g b o a j m f m v f i b m a i b c b ` l ` m v c b

LA

Fig. 8
^ h l b v r b b h ` m l a i b m j h b r ` l ^ k  ` m v c b n b s j _ b h ` n j k a g e l b v r b b h a i b w j r _ k c ` h w j r ` m l r b c ` a ^

CFA
h ^ h r b c ` a ^ } b c d c ` r v b ` m b ` a b l } ` c k b j w a i b s i ^ y w c j q o i b m r j k v i ^ m v ` m l ` n j k a e l b v r b b h ^ m w ^ m ^ h i ^ m v f h ^ q } b a j v ^ } b h

FA Roughing: FA F H FR FH
s j h

FR
e e 

FH
h s j h g e b o a j m 

CFA CFA

Finishing: FA FH FR FH
i b w j r s b r ` r ` { b h f p m v r ^ m l

CFA CFA FH FC FH
x ^ h j n b q

} ` r c `

FH FC
s ` k h b v r ^ m l ^ m v v r ^ a h i ` } b m b v ` a ^ } b r ` { b h j w a i b j r l b r g a j

Forces and Tool-life.

a ^ s k c ` r ^ m a b r b h a n b s ` k h b j w

FH FC
j j c c ^ w b f

FH FC
1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

H-CURVE

FH/FC

ECT, mm

FH FC
j a j r j r h k h

ECT
y ` m d ` r b h i j o m ^ m ` m l

Figs. 11a
i b r b x ` m l a j j c c ^ w b ` r b y c j a a b l } b ` a l ^ w w b r b m a } ` c k b h j w s k a a ^ m v h y b b

FH FC

ECT

11b V
q l

ECT
f

FH FC
1000

H-CURVE

100

T, min

10

0.1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

ECT, mm

ECT
c h b o i b r b s j m w ^ r _ a i ` a a i b x w k m s

The Force Relationship:

a ^ j m s ` m n b l b a b r _ ^ m b l k h ^ m v a i b a j j c c ^ w b s j m h a ` m a h ^ m a r j l

FH FC
k s b l y r b } ^

H K M L N0
q q q q

LF L

F H a F C
 a i b r ` { b ` m

K y

(x H) M

LF (N L
^ m a k r k b h } b

Lx )
m v ^ h ` y y r j ^ _ ` a b c d e f a j e f ` m l k h

a
x ^ h e a j e f ` a a ` ^ m h ^ a _ ` ^ _ k _ } ` c r h 

LF L
a j j c c ^ w b } b r d h ^ _

FC
a ^ j m i ` h _ ` ^ _ ` ` m l a i b r b c ` a ^ j m h i ^ y h ^ m q a i b a j j c c ^ w b w k m s a ^ j m h h i j o m ^ m a i b a j j c c

a ECT
a i b ^ w b y c

H
a i r b b w j r s b r ` a ^ j y ` m b h ^ m q

Figs. 6a 6b
q

6c

1000
LF/L = 5

LF/L = 10

LF/L = 20

T , minutes

100

10

1 0.1 1

FH/FC

FH FC
` s s j r l ^ m v a j ` h w j c c j o h

FH FC

Equation (5)

FH aF C

LF
     

Equation (4a) (4b) Equation (5) Fig. 12

LF

LF L

COMP

Surface Finish Ra and Tool-life.

Ra

10

V = 475 V = 320 V = 234 V = 171 V = 168 V = 144 V = 120

Ra, mm

0.1 0.001

0.01

0.1

ECT, mm

Ra

ECT

Fig. 13

Ra

ECT

Ra Fig. 14

Fig. 15 Ra

ECT

Ra

Ra

ECT

Ra Ra
     

r r
     

5 4.5 4 3.5 3

10

Ra

Ra

2.5 2 1.5 1 0.5 0 0 0.05

U

1 V = 260

V = 170, r = 0.8 V = 170, r = 1.2 V = 170, r = 1.6

V = 215

V = 175
0.1

0.1

0.15

0.2

0.25

0.01

0.1

ECT

ECT, mm

Ra
 " % #

ECT

Ra

ECT
. /

r
 ) ( $ &

r
# 

"

&

'

"

&

'

Equation (6)
 & (  " #    '   !

Ra
 & '  

Ra
 ( & 

'

&

<

ECT
& <  & * ( ! # 

&

Example 1:
<  *  !         .

&

&

'

<

&

&

"

r
  

>

r
. @ *

'

"

'

&

<

"

&

&

'

'

&

<

'

r2
" *   & ( * !

r1
+    + (

>

&

&

"

R a Ra Ra Ra
? 7 D B C 7 D B +

&

'

<

&

>

>

Ra
. >   '

&

&

ECT
<  & * ( & 

&

&

Ra
< &  

Ra
D  & ( (  &

Ra
  !

>

Ra
"  

<

Example 2: r
= *   & '   !   '    (     =     & ( (  (  

&

&

'

"

&

>

r
. L  # 

r2
" *   & ( * !

r1
+    + (

>

&

"

R a Ra Ra Ra
? 7 D B C 7 D B +

&

'

<

&

>

>

Ra
. ? > & * !

&

&

ECT
#  * # * #  N ( * !

&

&

Ra ECT
( & &

Ra
D <   ) * 

* ) . A

Ra
  "  ( #

Ra
( & & 

&

&

&

&

15
 & * ( & < &  * #

"

&

"

"

'

&

Ra Figs. 6b
 &  #   $   

&

6c
$ " & 

"

&

Figs. 13 Fig. 16 Ra
( +  & ( #  &

<

"

"

'

&

&

ECT

<

<

&

&

'

10

Ra

ECT = 0.03 ECT = 0.08 ECT = 0.12 ECT = 0.18 ECT = 0.30

0.1 1 10 100 1000

T, min.
Q

Ra
< & <

T
+ < 

ECT
 & +  ( T

The Surface Finish Relationship: Ra

 & " * #    (   $ * ( '   #   " O "  ' & *  + '   * X

&

&

&

&

&

'

&

<

"

"

"

y
N  &  &

K Ra
*  +

x H Ra M Ra
[ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ Z *  & #  &

(N
(   '

Ra
* < & ' 

L Ra ) ( R a )
] ^   (  <   ( # *  # ( .

KRA HRA MRA NORA

LRA

Shape of Tool-life Relationships for Turning, Milling, Drilling and Grinding OperationsOverview. V ECT T
A (  ! ! *  %  ' #  &  &  &  * " (  * $ & (  ' #   " O "  ' & <   ) & ( O O E   * $  ( F '   #  & !  ( # <  ! !   ! * <       $   < & ( ( & (   < "  +        +     ( (   N    +   " & , "   *   #  !  < <    +   * # & (  

Fig. 17a

Fig. 17h

1000

1000

V, m/min.

V, m/min

100

100

Tool life, T (minutes) T = 15

Tool-life (minutes)
T = 15 T = 45 T = 120 10 0.01
o p q r s t r v w w x y x p z { z w | } ~

T = 45 T =120
10 0.01

0.1

0.1

1
p  q x w y u x x w } { { x

ECT, mm
o p q r s t u r v w w x y x p z { z w | } ~ |  p  q u } p | w 

ECT , mm
|  p { ~ p  q w u } { u | p {

1000 Tool-life (minutes) T = 15 T = 45 T = 120

1000 T = 15 T = 45 T = 120

100

100

V, m/min.
10

V, m/min

10

1
1 0.01 0.1 1

0.01

0.1

ECT, mm
o p q r s t r v w w x y x p z { z w | {  y p x x p  q s } { { x o p q r s t r v w w x y x p z { z w | { 

ECT, mm
y p x x p  q x w y u x x w } { { x

1000

1000

100

10

V, m/min

V,m/min.

T = 45
T = 15 T = 45 T = 120
1 0.01 0.1 1
o p q r s

T = 120 T = 15
100 0.01
t z r v w w x y x p z { z w | z u { y

0.1
p x x p  q s } { { x

ECT, mm
o p q r s t { r v w w x y x p z { z w | {  y p x x p  q x w y u x x w } { { x

1000

10000

T = 15 T = 45 T = 120 100

V, m/min.

V m/min
10

1000

T = 30 T = 10 T=1
1 0.01 0.1 1

100
ECT, mm

0.00001

0.0001

0.001

ECT, mm
o p q r s t r { { x y x p z { p  q | p  p  q } w w x y } { { x

Calculation Of Optimized Values Of Tool-life, Feed And Cutting Speed Minimum Cost.

TO

fO

VO

f V ECT

ECTO CTOT

Fig. 6c

HR

CE HR

TRPL

HR

Production Rate.

The Cost Function.

CTOT

ECT

Fig.

18a

tc

CTOOL

CTOT

0.3 CTOT 0.25 T varies

CTOOL T varies

Total Cost

Cost of Face Milling Operation, $

0.2

Minimum cost

9.81

0.027

0.164

30

356

0.15

Cost of Cutting Time

0.1

Hourly Rate = 60$/hour

0.05

Tooling Cost 0 5 7

11

13

15

CC

CTOOL tc

CTOOL

CTOT

HR

tc

HR

0.5 0.45 0.4 0.35

Cost, $

CTOT 1 Tool CTOT 2 Tools

CTOT 4 Tools

0.3 0.25 0.2 0.15 0.1 0.05 0 5 6 7 8 9 10 11 12 13 14 15

Cutting time, seconds

HR

 !     $   ) !

"

Fig. 18b
"     "   
         ! " &     

&

'

"

Fig. 18a
 *             !                   

'

"

"

HR
      

"

"

"

"

Global Optimum.
  
   "           ,    
       "       
           

"

&

"

&

&

"

"

"

ECTmax
"      *    
 

"

Fig. 7
         !              
  !              

&

"

TO
"

<

>

>

TO
F P

>

0.6
G

fz

V
N

tc

CTOOL

CTOT

0.55

CTOOL T = 22 CTOT T = 22
CTOOL T varies CTOT T varies

0.5

0.45

0.4

Minimum Cost

0.60

119

4.903

0.0186

0.0867

Cost, $

0.35

0.3

>

>

fz

V
X

tc

T CTOOL

>

0.25

CTOT

0.2

0.15
A Y R U > F I Z F = [ F F H

>

0.1
A

fz tc

G G

0.05

CTOOL

CTOT

0 0 5 10 15 20 25 30

Cutting Time, seconds

fz

Minimum Cost

9.815

0.027

0.164

30

357

Fig. 19
  . /  0  %   

TO
2 2 3   

'

'

fO
      

"

VO
       "

"

tcO
  4    

fO
. 5     

"

VO
      


"

TO
  

 

 

tcO
/  / 6 3     

"

&

&

"

&

&

'

tc CE T
2 7 0 1

Calculation of Cost of Cutting and Grinding Operations

"

tc
.     

"

T
. 1 3  7 2

'

'

"

'

'

'

'

'

'

G


"

Optimization Models, Economic Tool-life when Feed is Constant.

       !              
 !                             !    " ) _            
                                              ! 

"

HR
 
        

"

"

TE
  

"

"

ECT
  #    ,      8 `

VT
 

CTOT

Economic tool-life: TE TV n
 1 "  . 2 2 1 "  1    "  

Economic cutting speed: TEn VE

   . a  
    ,       "

n
       

"

n,
      

23
  ! 0 /

1026
      " 

&

Table 5b TV
  
  ,       !  

1034
            

1058 CE HR
   "               "     

Tables 1 Table 15e TV TRPL


  
 "       . c                

TRPL
 "         "

"

"

"

"

TV
    


&

CE
   

"

HR
   "

"

&

Fig. 20a
              


"

TV

"

60
TE

50

40

TE

30

20

10

0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

fz , mm

TE

fz

CE
  !    

HR
" !       

TV HR
"  
   "

"

TV
      #  

"

"

TE VE
   #    

TV
     "  

TRPL TRPL HR
     &   2  ~       

"

CE
      

n
   _

TE
      

"

"

&

&

1000

T, minutes

100

10
ECT = 1.54

ECT = 0.51

ECT = 0.8

1 10 100 1000

V, m/min


ECT
        

&

Fig. 20a fz
   
" " " /  6 2 /  0

"

TE
 #  &    

ECT
.      8       

"

Fig. 20b
 9 1
 . 0 /   

&

TV z
.
.      

"

HR

     

"

D
. 2
  &  

'

"

ar
.      &   

HR
    

n
  "    

&

Global Optimum, Graphical Method.

   !

              

 !         !      "                   !         

ECT
"

"

tc V ECT
.        

tc

"

SMRR V
. 

&

"

V

      a 

ECT
  !   

tc
  


C
V ECT
    !

  !           

Equation (7)
      !

      !
" 
  !     !

V ECT
  ,   

&

G
       

"

&

Note:
$        

a CEL
1  
 

ECT
  ,   

"

"

&

V ECT T
 " " . 2 6 2 (       6         "    # 

"

Fig. 21
" "  0 / 2 / /    !              

&

"

"

G
        


"

"

'

"

"

"

T
.     


"

"

&

&

"

ECT

&

&

1000

Constant cutting time increasing going down 45 Degrees

G-CURVE

V, m/min

T=1 T=5 T=15 T=30 T=60 100 0.1



ECT, mm

V ECT
  &   "   

Global Optimum, Mathematical Method. T ECT CTOT

      
 
   !          8 " ,               "    8

V


"

Optimum tool-life:
TO nO

  

TV n

TO )

  

M (L


N
 %

L( M
 !    

H)
        " &    
 

nO
     

ECT
  
               

Optimum cutting speed:

VO

(H L

N )

TO

M L ( TO )

Optimum ECT:
ECT O
  &    !             
                     #   
         

     

H


M (L
        

( TO )
   

)
  #           "   

C TOT

   #     

"

&

&

"

'

"

&

&

&

Determination Of Machine Settings And Calculation Of Costs

SPEED AND

FEED TABLES

1021

tc

tc

FR

f Nch

FR

ctool

ctot

f= T= V=

Nomenclature fE = TE = VE =

fO = TO =

VO =

ctool = ctot = FR = N= Nch = tc = tcyc =

CTOOL = CTOT =

TC = TCYC =

ti = z=

CC = CCH = CE = HR = TV = TRPL = Note:

TC

tc

TC Nch tc CTOT Nch

ctot

Formulas Valid For All Operation Types Including Grinding Calculation of Cutting Time and Feed Rate Feed Rate: f FR f

Cutting time per piece: Note:

V ECT

tc

Dist FR

Dist f

Dist D Vf

Dist

ECT tc Dist D a tc CEL ECT V a Example 3, Cutting Time: Dist D FR tc

f a CEL ECT V

Scheduling of Tool Changes Number of parts before tool change: Nch T tc

Cycle time before tool change: TCYC Nch tc ti tcyc tc ti

tc

ti

Tool-life: T Nch tc

Example 4:

tc

ti

Nch

TCYC

Example 5:

tc

ti

Nch

T Nch tc

TCYC

Calculation of Cost of Cutting and Grinding Operations.

Cost of Cutting per Batch: CC HR TC TC TCch Nch tc tc HR

tc

Cost of Tool Changes per Batch: HR T RPL TC min C CH T min T TRPL

Cost of Tooling per Batch:

C TOOL

CE HR HR TC T

min hr hr min min min

Cost of Tooling + Tool Changes per Batch:

( C TOOL

C CH )

HR

T RPL TC

CE HR

Total Cost of Cutting per Batch: HR TC

T RPL

C TOT

CE HR T

Equivalent Tooling-cost Time, TV:

TV

T RPL

CE HR

( C TOOL

C CH )

HR

TC

TV T

C TOT CE

HR

TC

T V T

Cost per Edge, Tools for Regrinding ( CE

Cost per Edge, Tools with Inserts:

CE Note:

Example 6, Cost per Edge-Tools for Regrinding: CE

TV

TRPL

n


tcE
  

CE

TV

T RPL TE

TV n

CE HR



TE

tcE

( C TOOL

C CH )

HR

TC

TV T

C TOT

HR

TC

T V T

Example 7, Cost per Edge-Tools with Inserts:

CE

TV

TE

TV

TE

TV

#

TRPL

CE

&

&

&

&

'

'

&

&

&

tcE

( C TOOL

C CH )

HR

TC

TV T

C TOT

HR

TC

T V T

CTOOL CCH

CTOT

Example 8, Turning:

V1

T1

V2

T2

ti

Dist

n,
)

D V 1 T1

V2 T2n

V V

*

T T

TE

TV

TV

TE

TE
!

TV n

VE

)

VE ( TE ) n VE

! )

V ( T )n
* *

T n V T E
*

"

FR
"

f tcE Dist FR

"

V E D

"

NchE TE tcE TCYCE NchE tc ti

Variation Of Tooling And Total Cost With The Selection Of Feeds And Speeds

TE

ECT

VE

Note:

Principal Speed and Feed Tables

favg

Tables 1

23

Example 9, Converting Handbook Feed Values From Inches to Millimeters: favg fopt

Example 10, Using Handbook Tables to Find the Taylor Slope and Constant: Table 1 1026 Table 4a

/

1032

(V V ) (T T )
) *

V ( T )n
) )

(V V ) (T T )
) *

V ( T )n
) )

(V V ) (T T )
) *

V ( T )n
) )

n

/

(V V ) (T T )
) *

V ( T )n
) )

(V V ) (T T )
) *

V ( T )n
) )

Selection of Optimized Data. Fig. 22

TE

VE

1000
tc tcyc

100

# parts
CTOOL
CTOT

10

0.1

0.01

0.001 0.01

1

0.1

10

f, mm/rev

2

Example 11, Step by Step Procedure: Turning - Facing out: f n Example 10

TV

6

CE
< = > < L L L L L L L L L L L L L C < ? B

>

<

>

<

>

>

<

CE

L L

>

>

>

<

<

U L L L L L L L L L L

TRPL

HR TV TRPL

TV

TE TV

7

CE HR TE n

Example 10

VE

C TEn

CTOOL = HR TC CE T (CTOOL+CCH) = HR TC TRPL CE T TRPL CE T CTOT = HR TC

Example 12, Face Milling - Minimum Cost :

V ECT T Fig. 23a

1000

G-CURVE

V, m/min

100

T=5
T = 22

T = 120
10 0.1 1 10

ECT, mm
j k l m n o p m q r s s k t l u v w w x y u m z q { | s } } ~  ~ k w } t u s p t s

LA

G Fig. 6c Fig. 23a ECT ECT z fz ar D aa CEL ar D ECT fz ECT fz

aa CEL

0.6 0.5
T=5 T = 22 T = 120

0.4

tc

0.3

0.2 0.1

0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

fz
j k l m n o m q r s s k t l s k w v w v p s y u m w w x v w s } } s

Fig. 23a

fz

ECT

TO

fmax

Figs. 23c Table 1

23e

Figs. 23a

23e

0.31
T = 120

0.26

T = 22

T=5

0.21

CTOT, $

0.16

0.11

0.06

0.01 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

fz, mm
j k l m n o m { } s p ~ } u s y u m w w x s } } s

tc

fz

Figs. 23b

6

fz

Figs. 23c

TO

0.1
T=5

0.09
T = 22

0.08
T =120

0.07

Unit Tooling Cost, $

0.06 0.05 0.04 0.03 0.02 0.01 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

fz, mm
j k l m n o x m { } } ~ k t l } u s y w u r u w w x s } } s

Fig. 23d

0.3

0.25

CTOT, $

0.2

0.15

0.1

0.05

T = 120 T = 22 T=5 0 50 100 150 200 250 300 350 400 450 500

V, m/min
j k l m n o w m { } s p ~ } u s y u m r s s k t l u v w w x p s o } t u s p t s s } } ~  ~ k y w u | w w x y p k w u

Fig. 23e

V TO

VO

Table 1

Table 1. Face Milling, Total and Tooling Cost versus ECT, Feed/tooth fz, and Cutting Speed V, at Tool-lives 5, 22, and 120 minutes
T fz

T CTOOL V

T CTOOL V

ECT

CTOT

CTOT

CTOT

CTOOL

High-speed Machining Econometrics High-speed Machining - No Mystery.

Table 10

14

1043

Fig. 4

1135

ECT

T ECT

ECT

ECT

T ECT

Depth of Cut/Cutter Diameter, ar/D D

ar

Figs. 3

1041

Fig. 5 1042 Mean Chip Thickness, hm

ar D

hm

ar D

ECT

Figs. 6b

6c

ar D

FR

ar D

ECT

hm

ar D

ECT hm

ECT

ar D

Chip Geometry in End and Face Milling. Fig. 24

hm

AE

ar D

Face Milling

End Milling

hmax hm

AE

ar ar hmax hm AE

fz 2 ar --cos AE = 1 2 --D

fz ar --cos AE = 1 2 --D

ar D

ar D

ar D

AE

Table 2a

fz fz

ar D

ar D

fz fz hm ar D

ar D

ar D

ar D

ar D

fz fz hm

ar D

ar D

Fig. 24

ar D

AE

fz fz ar D

fz fz

ar D ar D

ar D

fz fz

ar D

hm

Fig. 25

6.5 6 5.5 5 4.5 4

fz/fz0 , Face Milling fz/fz0 , End Milling

fz/fz0

3.5 3 2.5 2 1.5 1 0.5 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

ar/D

ar D

Table 2a. Variation of Chip Thickness and fz/fz0 with ar/D

      
                  

e= z= fz0 = AE =
      

ar D
 

z= fz0 = AE = ar D
        

ar D
        

AE
    

hm fz
 ! "   

hm
  

ECT hm
#     

fz fz
 " $    

AE
    

hm fz
 ! "   

hm
  

ECT hm
     

fz fz
   

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

Table 2a

fz

fz fz

fz

hm

fz

fz fz

hm

ar D ar D

Mean Chip Thickness hm and Equivalent Chip Thickness ECT. ECT fz z ECT fz z ar D aa CEL ar aa CEL hm ECT hm z AE AE

hm ECT z AE AE ar D AE ar D Calculation of Equivalent Chip Thickness (ECT) versus Feed/tooth and Number of Table 2a ECT teeth.: Table 2b ar D ECT fz fz fz hm

ar D

hm

Formulas.

fz

Face milling: ECTF ECT0F z

fz

aa CEL

ECTF

fz

fz

ECTF ECT0F

z CEL aa

&

Table 2b. Variation of ECT, Chip Thickness and fz/fz0 with ar/D

      
             

ECT
     '   ( (  

ECT
   '

ar D
       

hm
   

fz fz
 " $  

ECT
 %     #

fz fz
 #  

hm
   

fz fz
    

ECT
   "   

fz fz
 "

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

aa CEL LA aa CEL

LA

LA

LA

Example, Face Milling: fz z LA ECT0F ECTF ECTF

ar ar D

ECTF Table 2b

aa CEL End milling: ECTE ECT0E z fz fz ECTE ECTE ECT0E z CEL aa fz aa CEL LA

ar

Example, High-speed End Milling: fz z ECTE ECT0E ECTE ECTE

ar D

Table 2b

Example, High-speed End Milling: fz z ECTE fz fz fz Figs. 26a 26d 26e Example, High-speed End Milling: ECTE fz z ECT0E ECT

D ar D

ar

Table 2b

ECTE

D ar D

ar

Table 2b

Example, Full Slot Milling: fz z

D ar D

ar

Table 2b

ECTE ECTE

Figs. 26a 26d

26e

Physics behind hm and ECT, Forces and Tool-life (T).

ECT

AE

ar D

Fig. 26a

ECT

ECT ar D fz fz

fz

fz

ECTE fz ar D

ECT

fz

hm

ar D

1000

T=5 T=15 T=45 T=180

H-CURVE G-CURVE

V, m/min

HS 6 HS 2 SL 2 SL 6

100 0.001

*

0.01

0.1

1

/

ECT, mm

Example:

Fig. 26a

fz

hm

ECTE

hm

ECTE

ar D

fz

ECT

hm

ECTE

<

>

fz
4 @ =

>

>

>

>

H
F

>

<

>

>

<

<

Feed Rate and Tool-life in High-speed Milling, Effect of ECT and Number of Teeth.
= @ B A @ = : 7 9 5 9 E E 3 3 6 > = : 3 7 < 6 9 5 3 A < 7 5 8 : ; 3 E 9 > C A @ = < 7 5 4 > 3 7 9 A < @ J 8 7 3 5 M L ? ? N 3 3 6 O = : 3 M

FR = z fz
E 3 3 6 7 5 8 > 4 C P T U U U

>

>

z fz
I G ; 3 > 3

f
P

>

>

<

<

>

>

V
R

<

>

>

10000

10000

FR, mm/min

1000

1000

FR, mm/min

T=5 T = 15 T = 45 T = 180

T=5 T = 15 T = 45 T = 180

H-CURVE

V, m/min

V, m/min

100

T=5 T = 15 T = 45 T= 180
0.01 0.1 1

100 0.01

T=5 T = 15 T = 45 T = 180

0.1

ECT, mm

*

ar/D

* _

ECT, ar D

/

ar D

: : 3 6 3 > < A <

9 >

T
< : ; G

Fig. 26b
= 5 6 C 7 T Z U E 3 3 6 > = : 3

<

>

>

FR
A : : 3 > 9 : ; 8

<

>

ar D Fig. 26c
R E > > 3 < 4 9 5 6 5 6 : 9

<

<

<

>

FR
: : 3 6 K = : 3 <

>

<

<

ECT
K P U U A 5 6 =

>

<

<

<

>

<

<

>

ar D
R = > 9 ? E = B : : ; = : : ;

>

<

Fig. 26b ar D
9 E R > = : 7 9 : 9 C

>

>

<

ECT ECT
K ^ P U C 3 = 5 B ; 7 6 K

Fig. 26c
= @ 9 5 8 : ; 3 < < K P U T U Z

H
F C C

>

<

<

fz fz
R

<

FR

>

>

>

<

100000
T = 45, SL

H-CURVE HS6

T = 45 T = 45, HS

FR , mm/min.

HS4 10000 HS2 SL6 SL4 SL2 1000 0.01

0.1

ECT, mm

ECT ar D

ar D

fz

fz

ar D

ar D

Fig. 26d

Fig. 26e

fz

ar D FR

FR

100000

FR , mm/min.

HS6 HS4 10000 HS2

SL6 SL4 SL2 1000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

T = 45, SL

T = 45, HS

Number teeth
t u v w x y { w t { { z | } ~ {  { | { | ~ { { ~ } | u ~ u u v

ar D
u ~

ar D

ar

ar D

Process Econometrics Comparison of High-speed and Slot End Milling .

Costs

ctot Determination Of Machine Settings And Calculation Of 1152

ctot HR Dist FR

TV T

TV =TRPL

CE HR

TRPL = CE = HR =

Fig. 27

ctot

ar D

ECT

1 H-CURVE minutes 2,4,6 teeth marked SL2 SL4 SL6 HS2

ctot , $

0.1 HS4 HS6 T = 45, z = 4, SL T = 45, z = 6, SL T = 45, z = 2, HS T = 45, z = 4, H T = 45, z = 6, HS 0.01 0.01 0.1 1

ECT, mm
t u v w x w ~ } | u ~ u u v

ar D
~ { { ~ }

ar D

fz

fz

fz

ar D

TV

Dist

FR

ctot

FR

ctot

FR

ctot

FR

ctot

SCREW MACHINES, BAND SAWS, CUTTING FLUIDS

Automatic Screw Machine Tool Operations Feeds and Speeds for Automatic Screw Machine Tools. Table 1

1171

Knurling in Automatic Screw Machines.

KNURLS AND KNURL

ING

991

Revolutions Required for Top Knurling.

c Example:

(R

r)

(R

r d)

Example:

c 1171

Table 1

Cams for Threading. Table 2

1173

Table

 

                

       

Table 1. Approximate Cutting Speeds and Feeds for Standard Automatic Screw Machine ToolsBrown and Sharpe

 

 

                       

            

"

 

 

"

"

"   

     

             

#  

  

Machinery's Handbook 29th Edition

  

     

  

 

  

"

" 

  

  

   

"

  " "  

"

 

   

"

"

"

                  

"

$ .

   % &

'

 

 % &

 % & % ! % &

&

  

$ 

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

"

 

  

         

      

Table 1. Approximate Cutting Speeds and Feeds for Standard Automatic Screw Machine ToolsBrown and Sharpe (Continued)

"

                

     

"

"

 

 

" 

"

  

"

  

"

            

           

"

  

  

          

  

         

        

                 

"

   #    

Machinery's Handbook 29th Edition

  "  

 

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"

 

 

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"

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"

   

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H D

<

 

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6 7

H  

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>

<

7 >

>

7 A

6 + +

< 6

>

>

<

G >

< 8

 G

E 4

0 

, 1 

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

  

  

"

#     

"

 

"      

  

"

 

# 

"

    

  

 

 

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"

"  

  

       

" 

  

    

 

    

   

             

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"

 

           

 

  

 

 

#    

 

 

  

"

"   

  

  

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"

   

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# 

 

             

 

     

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"

" 

 

Table 2. Spindle Revolutions and Cam Rise for Threading

 

"

 

 

 

  

      #

"

"  

  

"

" 

# 

"

 

"

"

"

# 

# 

# 

"

"

   

  

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"  

  

 

"

 

 "    

# 

Machinery's Handbook 29th Edition

"

"

"

"

  

 

 

 

 

          " #   

 "

"    

  

#        

  

#    

# 

"

"

"

"

+            

"

 

  

  

  

"

" 

  

 

"

 

# 

"

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# 

"

   

 

 

 

 

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"

 

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"

 

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"

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Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Practical Points on Cam and Tool Design.

Table 1

1171

Stock for Screw Machine Products.

Table 3

1176

F= L= W=

(L

W)

W= D= F=

W D

W D

W D

Table 3. Stock Required for Screw Machine Products

{ ~ } { v u  { ~ { } ~ ~ u { { ~ | {

k
u { { } z { |

Band Saw Blade Selection

30 35 40

29

26 25 24 23 28 27 22

21

20

.75 1.5 .75 1.5

19 18 17 16 15 14

45
.75 1.5

50 55 Inch 0 .1 .2 .3
800 900 1000 1250
14 18
14 18 10 14 8 12

700 600

mm
5 10 15 20 25 50 75

500 450 400 350 300 250 200 150 100

1.5 2.5

13 12
1.5 2.5

11 10 9

14 18 10 14

10 14 8 12 6 10 5 8 6 10

1.5 2.5

2 3
2 3

8 12

8
2 3

.4 .5 .6 .7

4 6
3 4

6 10

5 8
5 8 4 6 4 6

7 6

3 4

.8 .9 1 11 4

3 4

5
33 4

1 11 2 13 4 1 3 2 2 21 4 21 2 23 4 3 3 4

Courtesy of American Saw and Manufacturing Company

Example:


} ~

~ } ~ 

Tooth Forms.
} | }   } ~ }  }  } ~  ~ }

standard tooth
~ } } ~ ~

skip tooth
~ } }

} ~

hook tooth
 } ~ 

variable-tooth
 ~ }

variable positive tooth

~  } ~ ~ } ~

Set

Alternate set
}  } 

raker set is
~

vari-raker set,
} ~ } ~

Wavy set
} | }  } ~ 

Types of Blades.
 } ~

Carbon steel
} ~

blades
~

Bimetal blades
 }  

Tungsten carbide
} |

blades
 ~ 

carbide grit blade

} } ~ } |

Band Saw Speed and Feed Rate.

} } ~ } ~ }   } }  ~ }

30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 0 50

0.75 1.5 1.5 2.5

Cutting Rate (in.2/min)

23 34 46

58 8 12

100 150 200 250 300 350 400 450 500 550 600 Band Speed (ft/min)

Cutting Rates for Band Saws

 } ~ } ~ } ~  } ~ } ~ }  } } } ~ ~ ~ ~ ~ } 

Bimetal Band Saw Speeds for Cutting 4-Inch Material with Coolant

Bimetal Band Saw Speeds for Cutting 4-Inch Material with Coolant (Continued)



"

"

Example:



1181

Band Saw Blade Break-In.



&

'

100 90 80 70 60 50 40 30 20 10 0 ft/min. 40 m/min. 12

Starting Feed Rate

% of Normal Feed

80 24

120 37

160 49

200 61

240 73

280 85

320 98

360 110
cm2 645 580 515 450 385 320 260 195 130 65 0

Band Speed (Machinability)

in.2 100 90 80 70 60 50 40 30 20 10 0 ft/min. 40 m/min. 12

Total Break-In Area Required

Break-In Area

80 24

120 37

160 49

200 61

240 73

280 85

320 98

360 110

Band Speed (Machinability)

Cutting Fluids for Machining

 

'

Types of Cutting and Grinding Fluids.

~


Cutting Oils, Water-Miscible Fluids



Gases. Paste and Solid Lubricants.

Cutting Oils.
~


Water-Miscible Fluids. Emulsions or soluble oils

~


Chemical fluids



Semichemical fluids



'

Selection of Cutting Fluids for Different Materials and Operations.




Steels:

Application of Cutting Fluids




to Carbides



Stainless Steel:

Copper Alloys:

 

Monel Metal:
~


Aluminum Alloys:



'

Cast Iron:



Magnesium:

Grinding:
~


Broaching:



Cutting Fluids for Turning, Milling, Drilling and Tapping. Cutting Fluids Recommended for Machining Operations



Soluble Oils:



Base Oils:
~


<

Mineral Oils:



>

'

Cutting Fluids Recommended for Machining Operations

Material to be Cut

?

Turning
"

Milling

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

Material to be Cut

"

Drilling


Tapping

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

@ A

'

Application of Cutting Fluids to Carbides.

~


Cutting Fluids for Machining Magnesium.

~


<

'

Occupational Exposure To Metalworking Fluids

metalworking fluids
~  


Table 1

Table 1. Classes of Metalworking Fluids (MWFs)

 I

Straight oil

Soluble oil

Semisynthetic

Synthetic

Occupational Exposures to Metal Working Fluids (MWFs).

-

'

Fluid Selection, Use, and Application.

~ ~ ~ ~


<

'

Fluid Maintenance.



Personal Protective Clothing:

System Service:



Biocide Treatment:

Ventilation Systems:
 


'

Protective Clothing and Equipment:

-

Table 2. Respiratory Protection for Workers Exposed to MWF Aerosols*



U g

&

'

MACHINING NONFERROUS METALS AND NON-METALLIC MATERIALS

Nonferrous Metals Machining Aluminum.

 

'

Machining Magnesium.


Keen-edged tools should always be used. Feeds and Speeds for Magnesium:
~  ~
 

Lathe Tool Angles for Magnesium:

Parting Tools:

 

Milling Magnesium:
~ 


Drilling Magnesium:



Reaming Magnesium:



'

'

Tapping Magnesium:


n 

Threading Dies for Magnesium



Grinding Magnesium:



Machining Zinc Alloy Die-Castings.

~


Reaming:

Turning:

  

Machining Monel and Nickel Alloys.

~


'

'

Machining Copper Alloys.

Table 2
 ~ z


515
| 

Table 3

 

519



Machining Non-metals Machining Hard Rubber.



Drilling of hard rubber



Piercing and blanking



Formica Machining.
~ ~


m 

>

'

'

Micarta Machining.



Ultrasonic Machining.

GRINDING FEEDS AND SPEEDS

;

SMRR



l 




Basic Rules



V



equivalent chip thickness ECT



SMRR V



ECT

ECT
~ ~ ~ 

T
 ~

V
  ~

ar SMRR Vw ar ECT



Vw
~ ~


1132 Wheel life T and Grinding Ratio. grinding ratio

 

MACHINING ECONOMETRICS ECT



grinding ratio grinding ratio MRR W*



MRR
~

W*
~ ~

grinding ratio

grinding ratio SMRR T W* SMRR MRR SMRR T ECT SMRR V grinding ratio ECT V T W* T grinding ratio W W* ECT V ECT V Example 1: W* grinding ratio ECT T grinding ratio V ECT grinding ratio ECT SMRR V ECT in Grinding. ECT



ECT ar


z
~

aa

CEL

fz D

ECT
~


Dzf z a r a a CEL
| | | | | | | | | | | | | | | | | | | | | | | | |
 

ECT

 

ECT


SMRR
~

ECT
~

SMRR V
 ~ ~ ~


ECT



SMRR

ECT



SMRR
~


SMRR
-

FR

Work Speed and Depth of Cut Selection: SMRR ar




Vw Fig. 1

1000
SMRR = 100 SMRR = 200 SMRR = 500 SMRR = 750 SMRR = 1000 SMRR = 1500 SMRR = 2000

100

Vw, m/min
10 1 0.001

0.01

0.1

ar, mm

Vw

ar



Fig. 1
~

SMRR



SMRR


SMRR


ar
~

Wheel Life Relationships and Optimum Grinding Data. Figs. 2a 2b T Fig. 2a V ECT
~


2c V
~

ECT T
|


TV
| 


ECT

T ECT
|


V ECT
|


H
|

100
ECT 105
ECT = 17 ECT = 33 ECT = 50 ECT = 75

T, minutes

10

1 100

1000

10000


V m/min

T
~

V ECT

Example 2:
 ~ ~
=

SMRR V ECT Fig. 2a SMRR

ECT
=

1000

100

V = 4600 V = 3600 V = 2907 V = 2220 V = 1800 V = 1500

H-CURVE

G-CURVE

T, min
10 1 0.00001

0.0001

0.001

ECT, mm

ECT V


Fig. 2b

ECT

Example 3: Fig. 2b

ECT

H Fig. 2c

ECT

10000 T = 30 T = 10 T=1

V, m/min

H-CURVE 1000 G-CURVE

100 0.00001 0.0001 0.001

ECT, mm

ECT T

Optimum grinding data for roughing V ECT G G T TV TRPL TV CE HR Minimum cost conditions occur G VO

Fig. 2c

C E HR

TRPL

TO

ECT SMRR

Fig. 1

ar

Vw

Fig. 3

ECT

ECT

SMRR

SMRR

ECT

Fig. 2c

SMRR

ECT

ECT

V ECT

10000 Vw a, T = 30, IncX Vw a, T = 10, IncX Vw a, T = 30, M4 Vw a, T = 10, M4 Vw a, T = 30, T-15 Vw a, T = 10, T-15 Vw a, T = 30, 1020 Unh Vw a, T = 10, 1020 Unh 1000

SMRR mm3/mm/min

Optimum = G-CURVE

H-CURVE

100 100

1000

10000

V m/min

Surface Finish, Ra. Fig. 4 Ra

ECT

ECT

ECT

10

Ra, mm

T=1 T=5 T = 15 T = 45 T = 100

0.1 0.00001 0.0001 0.001

ECT, mm

Ra

ECT

Fig. 5 Ra

ECT

Figs. 4

ECT

ECT

ECT

fs

Ra

SMRR

10

Ra, mm

ECT = 0.00004 ECT = 0.000085 ECT = 0.00013 ECT = 0.00019 ECT = 0.005

0.1 1 10 100 1000

T, minutes

Ra

T ECT

Example 4, Specific Metal Removal Rates and Work Speeds in Rough and Finish Grinding: ECT

ar


ar


ECT
 

V10
 

SMRR10

Vw

Fig. 6

10000

Ra = 0.03 Ra = 0.05 Ra 0.16 Ra = 0.25 Ra = 0.55 Ra = 1.1



V, m/min

1000

100

10

100

1000

Mesh

Ra

Spark-out Time. Fig. 7

Equivalent Diameter (Work Conformity) Factor:

De D

D Dw

"

"

&

&

'

'

&

&

'

Sparkout Tsp, minutes

T=1 T=5 T = 10 T = 100

0.1

0.01

0.1

10

100

Kst, N/mm 10
Y Z [ \ o \ ^ _ p c q f r k k Z s ` \ k ` s k Z b b d ` g h h t h h h

1
` ` j x j Z b `

T
0 2 : ; 4

<

>

<

<

>

<

<

<

De
. 1 2

<

<

<

<

<

<

<

De
0 1 2

<

<

Grinding Cutting Forces, Torque and Power.

A 5 0 0 / 4 7 8 9 : A 2 @ 0 9 : F 5 2 ; 4 = : 2 F 5 / : 2 = 3 ; A 1 / 4 / 4 7 > 9 . 2

<

<

<

<

Estimating Machining
9 : 6 > 2 A / 8 / A 2 4 2 : 7 B @ ; : 2 / < < / 4 7 ; 4 = = : / < < / 4 7 E Q 1 / 6

Power
; > > : 9 ? / / 6 > : / 3 ;

>

<

Kc
@ 7 : / 4 = C ; < 5 2

>

<

<

ECT
2 ; 4 7 9 : 7 : / 4

<

<

<

<

<

N W ; 4 = / 4 = /

P > 0 9 A 5 0 0 /

Kc
X L L : 2 :

<

<

<

<

<

<

<

<

>

<

<

68000 67000 66000

V = 6120 V = 4320 V = 2183 V = 1000

Kc , Newton/mm2

65000 64000 63000 62000 61000 60000 59000 0.00001 0.0001 0.001

ECT, mm
Y Z [ \ ] \ ^ _ ` a Z b Z a [ c Z d e Z d [ b f c a `

Kc
: A 2 6

ECT V
i : B . / 0 1 @ . 1 2 : 2

<

>

<

>

V
; 0 = A ;

>

<

Fig. 8
K L L L ; 4 ; < 5 3 /

ECT Kc
@ 6 > V L L 3 9 ? / = 2 6 > 2 2 =

<

<

>

<

ECT
: = 2 4 2 : 2 < ; 0 / C

<

>

<

<

<

>

<

>

<

<

<

<

Example 5:
G . / = 0 1 9 8 A 5 0 H

ECT
U V L L L 3

<

CEL

Kc
n

ECT CEL

Kc

FH FC

FH

FC

FH

FH FC

Fig. 9

FH FC

ECT Fig. 8

2.1
V = 6120 V = 4320 V = 2183 V = 1000

FH/Fc

1.9 0.00001 0.0001 0.001

ECT, mm

FH/FC

ECT

Fig. 8

Fig. 9 ECT

Kc

FH FC ECT

Figs. 2a 2b 2c

ECT 3

ECT

Grinding Data Selection Including Wheel Life

Table 1 STANDARD STEELS

396

American National Standard Grinding

Wheel Markings

1218

1219

The Selection of Grinding Wheels Cutting Fluids for Machining

1182

Note:

Safe Operating Speeds

1248

Table 1. Grindability Groups

SMRR

User Calibration of Recommendations

ECT

SMRR

T,

Vw

TV

ECT

V1 V10 SMRR

V100

SMRR1 SMRR10

SMRR100

ECT

ECT

ECT ECT V1

V10

VT V100

Side Feed, Roughing and Finishing.

fs

FR

Finishing: ar

ar

fs

Ra

Figs. 4 5

Terms and Definitions aa = ar = C= CEL = CU = D= DIST = dw = ECT =

f ar V Vw f s

) Vw fs ( ar V Vw ar V SMRR V z fz ar aa CEL D V Vw ar

fs

FR =

fs RPMw fi RPMw

fi = fs =

C Width

aa CEL Grinding ratio = MRRW* SMRR TW* ECT V TW* SMRR T fs ar Vw MRR = SMRR = MRR C Width ar Vw Note:

T, TU = tc =

Grinding ratio W DISTFR

ECT V

DISTFR tsp DISTFR tsp

tsp = V,VU = Vw,VwU = W* = Width = RPM = RPMw =

SMRR

ar

VD Vw Dw

Relative Grindability.

Table 2

Table 2. Grindability Overview

Vw

ECT

V10

SMRR10

ar

Finishing Depth ar

V600

SMRR600 SMRR600

V600

Procedure to Determine Data. ECT

ECT H

ECT

V10

V100

n (V T(desired)) 0.26 =

ECT

V1

V1 V10 = V100 =

Example 6:

ECT

V10

V100

V15

V45

The Tables are arranged in 3 sections: V10 V1

ECT

V100

V1

ECT

SMRR100 SMRR10 ECT

SMRR1

SMRR

ECT

Table 1. Group 1Unhardened Steels

  

ECT

ECT

ECT

ECT

VT

SMRR

VT

SMRR

VT

SMRR

VT

SMRR

10

4905

835

3830

1265

2960

1480

2135

1600

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000

SMRR, mm3/mm/min

T=1 min. T=10 min. 1000

T, minutes

10

T=100 ECT = 17 ECT = 33 ECT = 50 ECT = 75 100 1000 10000

1 1000

V, m/min

10000

V, m/min

TV

SMRR

V T

Table 2. Group 2Stainless Steels

  

ECT

ECT

ECT

ECT

VT

SMRR

VT

SMRR

VT

SMRR

VT

SMRR

10

1250

210

1080

355

825

415

555

415

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000 ECT = 17 ECT = 33 ECT = 50 ECT = 75

SMRR, mm3/mm/min

T, minutes

10

1000

1 100

100
1000 10000

100

1000

10000

V, m/min

V, m/min

TV

SMRR

V T

"

Table 3. Group 3Cast Iron

  

ECT
 . / 0 1 

&

'

&

&

&

ECT
. / 0 &

&

'

&

&

&

ECT
. / 0 &

&

'

&

&

&

&

ECT
. / 0 ,

&

'

&

&

&

&

VT
+ 6 + ,

SMRR
, , & 6

VT
, 6 ,

SMRR
3 + , ( 7

VT
, &

SMRR
7 ) , ( 5

VT
( &

SMRR
( & , ,

&

&

10
( (

5885
& ) ( &

1000
( 3 6 &

4595
3 + 4 & 6

1515
) 4 & 4

3550
5 4 , +

1775
6 + & 5

2565
4 4 , +

1920
, & &

100

10000 ECT = 17 ECT = 33 ECT = 50 ECT = 75 T = 1 min

SMRR, mm3/mm/min

T, minutes

10

1000 T = 10 min T = 100 min ECT = 17 ECT = 33 ECT = 50 ECT = 75 100 1000

1 1000

V, m/min
8 9 : 2 ' + '

10000
8 9

V, m/min
0 = '

10000
9 / ? 1 @ 0

TV
; A

'

<

'

SMRR
E B C F C

V T
> C H C I

&

&

>

&

>

Table 4. Group 4Tool Steels,

ECT
       . / 0   % & ' & & & ( ) * *

ECT
. / 0 &

&

'

&

&

&

ECT
. / 0 ,

&

'

&

&

&

&

ECT
. / 0 &

&

'

&

&

&

&

&

VT
( & & 6 6 5 ,

SMRR
+ 3 & ( )

VT
, ,

SMRR
, 3 & ( +

VT
, ,

SMRR
4 3 & 7

VT
3 &

SMRR
) + ,

10
( )

4090
5 5 & (

695
6 4 ,

3190
, 3 & ,

1055
( 7 ( , 5

2465
5 7 & 6

1235
6 5 , +

1780
6 5 & 6

1335
5 + &

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000

SMRR, mm3/mm/min

T = 1 min T = 10 min 1000

T, minutes

10

T = 100 min

ECT = 17 ECT = 33 ECT = 50 ECT = 75 10000

9 / ? 1 @ 0

1 1000 10000

100

V, m/min
8 9 : 2 ' 5 '

1000

V, m/min
0 = '

TV
;

'

<

'

SMRR

V T
>

&

&

>

&

>

"

Table 5. Group 5Tool Steels,

ECT
V W [ U T U Z . / 0 S X Y % & ' & & & ( ) * *

ECT
. / 0 ,

&

'

&

&

&

ECT
. / 0 5

&

'

&

&

&

&

ECT
. / 0 &

&

'

&

&

&

&

VT
( & & 6 & 6 &

SMRR
+ 5 , (

VT
, 3 &

SMRR
, 6 & ( 6

VT
6 &

SMRR
4 ( & 3

VT
3 &

SMRR
4 4 &

10
( 4

3680
4 7 , (

625
( 5 &

2870
, 6 6 , (

945
) 6 , 5

2220
& 5 & 6

1110
& 6 & 6

1600
7 ( , 6

1200
( 3 ,

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000

10

SMRR, mm3/mm/min

T, minutes

1000

ECT = 17 ECT = 33 ECT = 50 ECT = 75 100 1000

1 1000

V, m/min
8 9 : 2 ' , '

10000
8 9 :

V, m/min
0 = '

10000
9 / ? 1 @ 0

TV
;

'

<

'

SMRR
P C A O

V T
> P C N

&

&

>

&

>

Table 6. Group 6Tool Steels,

ECT
V W [ U T U Z . / 0 S X Y R % & ' & & & ( ) * *

ECT
. / 0 &

&

'

&

&

&

ECT
. / 0 &

&

'

&

&

&

&

ECT
. / 0 ,

&

'

&

&

&

VT
( & & ( 4 & &

SMRR
6 ) & ( 5

VT
( ,

SMRR
5 4 , ( &

VT
3 ,

SMRR
, 5 & )

VT
6 ,

SMRR
, 5 &

10
(

2910
, 6 7 & 7

495
& & 5

2580
4 7 & (

850
, , & +

1970
, 3 , (

985
) 7 , 6

1315
+ 7 , (

985
) 7 ,

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000

SMRR, mm3/mm/min

T, minutes

10

1000

ECT = 17 ECT = 33 ECT = 50 ECT = 75 100 1000 10000

1 1000
8 9 : 2 . ? _

V, m/min
. . a b 1 @ @ a 0 ' 4 ' ] ^ 4 `

10000

V, m/min
8 9 : ' 4 < '

TV
;

SMRR

'

V T
>

&

&

>

&

>

Table 7. Group 7Tool Steels,

ECT
V W [ U T U Z | } ~  S X Y R t u v u u u w x y y

ECT
| } ~  u

ECT
| } ~  u

ECT
| } ~  {

VT
w u u {

SMRR
w w { {

VT
{

SMRR
w {

VT
{ {

SMRR
{ z

VT
u {

SMRR
z u

10
w

1250
x u z

210
{

1080
w x u

355
{ u w

825
{ u { x

415
{ u w

555
u w u x

415
u

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000 ETC = 17 ETC = 33

SMRR, mm3/mm/min

ETC = 50 ETC = 75

T, minutes

10

1000

1 100

100

1000

10000

100

1000

10000

V, m/min
v x v

V, m/min
v x v

TV

SMRR

V T
r

Table 8. Group 8Heat Resistant Alloys,

ECT
V W [ U T U Z | } ~  S X Y R t u v u u u w x y y

ECT
| } ~  u

ECT
| } ~  u

ECT
| } ~  u

VT
{ u

SMRR
w w u {

VT
x {

SMRR
w u

VT
{ u

SMRR
{ z

VT
w {

SMRR
z {

10
w

1185
w { u z

200
{

1045
w u u

345
{ w

820
u x

410
{ w

570
u z { x

425
u

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000 ETC = 17 ETC = 33 ETC = 50 ETC = 75

10

SMRR, mm3/mm/min
10000

T, minutes

1000

1 100 1000

100 100

1000

10000
~ 

V, m/min
v v

V, m/min
v v

TV

SMRR

V T

Table 9. Group 9Carbide Materials,

ECT
| } ~  t u v u u u u y y

ECT
| } ~  u

ECT
| } ~  u

ECT
| } ~  {

VT
u u w z {

SMRR
z u w

VT
w {

SMRR
z { x

VT
u

SMRR
u z

VT
u

SMRR
z u

10000 ECT = 2 ECT = 3 ECT = 5 ECT = 8 1000

1000

SMRR, mm3/mm/min

ECT = 2 ECT = 3 ECT = 5 ECT = 8

T, minutes

100

100

10 100

1000

10000

10 100 1000 10000

V, m/min
v v

V, m/min
v v

TV

SMRR
r

V T
r

Table 10. Group 10 Ceramic Materials,

ECT
| } ~  t u v u u u u y y

ECT
| } ~  u

ECT
| } ~  u

ECT
| } ~  u

VT
z {

SMRR
z

VT
z {

SMRR
w u

VT
{

SMRR
w z

VT
w u

SMRR
w x

10000 ECT = 2 ECT = 3 ECT = 5 ECT = 8 1000

100 ECT = 2 ECT = 3 ECT = 5 ECT = 8

100

SMRR, mm3/mm/min
10
10000

T, minutes
10 100

1000

100

1000

10000
~ 

V, m/min
v w u v

V, m/min
v w u v

TV

SMRR

V T

User Calibration of Recommendations

Table 11

Fig. 12

TU

VU

VwU

ar

TU

VU

ar

VwU

ECT VwU ar VU

V10U

V100U

VU TU

TU

V10U V100U

V10

V100

ECT

V1 V10

V100

VU TU

V10U

V100U

Example 7:

VU

TU

ECT

Standard Table Data, Group 6 Material

ECT

ECT

ECT

ECT

VT


SMRR

VT

SMRR

VT


SMRR

VT

SMRR

10

2910

495

2580


850

1970


985

1315

985

100 ECT = 17 ECT = 33 ECT = 50 ECT = 75

10000

SMRR, mm3/mm/min

T, minutes

10

1000

ECT = 17 ECT = 33 ECT = 50 ECT = 75 100 1000 10000

1 1000
   

V, m/min
         

10000

V, m/min
  

TV


SMRR

V T


Calculation Procedure V1U V10U, V100U

SMRR1U SMRR10U, SMRR100U

ECT


V1U

VU TU


SMRR1U

V10U

SMRR10U

V100U ECT

SMRR100U

V1

Table 6

"

ECT

ECT

V1

V1U

V10U

V100U

SMRR1U SMRR10U, SMRR100U

ECT

V1U

V10U

V100U

SMRR1U SMRR10U ECT V1U



SMRR100U


V10U

V100U

SMRR1U SMRR10U ECT V1U



SMRR100U


V10U

V100U

SMRR1U SMRR10U

SMRR100U

ECT

V


T
 

ECT

T SMRR

V
$

 

Table 11. User Calculated Data, Group 6 Material

ECT
%

ECT
%

ECT
%

ECT
%

&

&

&

&

VT

SMRR


VT

SMRR



VT

SMRR

VT

SMRR

10

1640


279

1455


480
 

1110

555

740

555

'

100
ECT = 17 ECT = 33 ECT = 50 ECT = 75 ECTU = 17 ECTU = 33 ECTU = 50 ECTU = 75

T minutes

Standard V10 = 2910 for T = 10 minutes

10 TU = 7

1 1000
      

VU = 1800
(     ) 

V m/min
 ) ) ) *       +

10000
 

VU

TU

ECT

Optimization. ECT

TE

TV

TV TRPL

CE HR

TRPL

CE

HR

TV

TV

Grinding Cost, Optimization and Process Planning:

2

Table 12
4

Table 12. Wheel Life vs. Cost

  6 8  9 :  )  6  (   (   ;     6 8   7  + +   7 5  (   6               

<

<

>

>

GRINDING AND OTHER ABRASIVE PROCESSES

D

Bonded

Coated Loose,

Cleaning

Shaping, Sizing,

Surface finish improvement,

Separating,

Grinding Wheels

Abrasive Materials.

 G J ! G J

G 2 !

G J ! H G ! H

! K L G J

Cubic Boron Nitride (CBN)

1012

Bond Properties and Grinding Wheel Grades.

Vitrified bonds

"

"

Resinoid bonds
E

Rubber bonds

Metal bonds


! G J

Grinding wheel grades

N O

2 H

Grinding Wheel Structure.

N O

"

"

American National Standard Grinding Wheel Markings.

0 G 1

1243 Sequence of Markings.

Abrasive Letters:
! P 2

Grain Size:


    

Grade:
0

Structure:
!

Bond or Process:
3 L 3

"

3 L

3 G ! 3 G

Manufacturer's Record:
3

American National Standard Shapes and Sizes of Grinding Wheels.

G   2 2

Table 1a

Table 1b

Table 2

The Selection of Grinding Wheels.

Tables 3
2

Table 3

Table 4
2

preceding
! J

! J

Table 1a. Standard Shapes and Inch Size Ranges of Grinding Wheels ANSI B74.2-1982
^ W _ ` a Y \ b ` ] [ c d e W \ X W U Y V f W g ` \ ] W [ \ ] h i \ X j ` ]

Type 1. Straight Wheel

 ~

Z [

{ w

{ p

Type 2. Cylindrical Wheel

g [ \ Z ` q [ \ Z j ` q W Y g ` Z ` e X j X n [ e [ \ Y U V Y Z ` l

W
^ s a T r u a i t f i t u p { ` e Z W X Y V ] U W \ q V ` g Y X j W \ ` ] } Z [ | [ e

Table 1a. (Continued) Standard Shapes and Inch Size Ranges of Grinding Wheels ANSI B74.2-1982
^ W _ ` a Y \ b ` ] [ c d e W \ X W U Y V f W g ` \ ] W [ \ ] h i \ X j ` ]

Type 5. Wheel,
W \ b l T V V [ ] g [ \ Z W \ b Z j \ Z Y \ q c V Y \

i t a t T u a i t f i t u

Z [ |

Type 6. Straight-Cup Wheel

j [ ] ` q W g ` \ ] W [ \ W \ b Z j ` U e ` X ` q ` \ X ` [ ` e Z j ` q W Y g ` { {

W
z ] ] l o j `

W
^ t T u u i t u | Z [ d [ e Z Y x V ` g Y X j W \ ` ] h [ e b Y \ W X x [ \ q [ \ V y l

Type 7. Wheel,
a ` X ` ] ] ` ] Y V V Y \ q Y V ] [ \ Y e Z j W X n \ ` ] ] l

Table 1a. (Continued) Standard Shapes and Inch Size Ranges of Grinding Wheels ANSI B74.2-1982
^ W _ ` a Y \ b ` ] [ c d e W \ X W U Y V f W g ` \ ] W [ \ ] h i \ X j ` ]

Type 11. Flaring-Cup Wheel

Y V V Z Y U ` e ` q [ Z Y e q c e [ g Z j W X n ` e W \ Z j ` x Y X n l

| Z [

Type 12. Dish Wheel

c Y X ` [ c Z j ` j ` ` V h W \ Z j W ] Z y U ` l

Type 13. Saucer Wheel

e ` ] ` g x V W \ b Z j ` ] j Y U ` ` Y V Z j e [ b j [ Z l

U
Z Z

E
~

Type 16. Cone, Curved Side Type 17. Cone, Straight Side, Square Tip Type 17R. Cone, Straight Side, Round Tip R J
Y q W ] z k

{ {

Table 1a. (Continued) Standard Shapes and Inch Size Ranges of Grinding Wheels ANSI B74.2-1982
^ W _ ` a Y \ b ` ] [ c d e W \ X W U Y V f W g ` \ ] W [ \ ] h i \ X j ` ]

Type 18. Plug, Square End Type 18R. Plug, Round End R

Type 19. Plugs, Conical End, Square Tip Type 19R. Plugs, Conical End, Round Tip R J
W U a Y q W ] z w m k

{ {

Type 20. Wheel, Relieved One Side

W \ b j ` ` V h [ \ ` ] W q ` c V Y Z h Z j ` [ Z j ` e c V Y Z l

Z [

Type 21. Wheel, Relieved Two Sides

e ` V W ` ` q Z [ Y c V Y Z l

Type 22. Wheel, Relieved One Side, Recessed Other Side

v \ ` ] W q ` e ` V W ` ` q Z [ Y c V Y Z l

Type 23. Wheel, Relieved and Recessed Same Side

j ` [ Z j ` e ] W q ` W ] ] Z e Y W b j Z l m

Table 1a. (Continued) Standard Shapes and Inch Size Ranges of Grinding Wheels ANSI B74.2-1982
^ W _ ` a Y \ b ` ] [ c d e W \ X W U Y V f W g ` \ ] W [ \ ] h i \ X j ` ]

Type 24. Wheel, Relieved and Recessed One Side, Recessed Other Side
v \ ` ] W q ` e ` X ` ] ] ` q h Z j ` [ Z j ] W q ` W ] e ` V W ` ` q Z [ Y e ` X ` ] ] l

Type 25. Wheel, Relieved and Recessed One Side, Relieved Other Side
v \ ` ] W q ` e ` V W ` ` q Z [ Y c V Y Z h Z [ Z j ` e ] W q ` e ` V W ` ` q Z [ Y e ` X ` ] ] l

Type 26. Wheel, Relieved and Recessed Both Sides

TYPES 27 & 27A. Wheel, Depressed Center Portable Grinding:

l u e W \ q W \ b \ [ e g Y V V y { X [ \ Z Y X Z W Z j [ e n Y Z Y U U e [ l Y Y \ b V ` [ c Z j ` j ` ` V l T l

Cutting-off:

{ {

E
s

W c

U
Z j W

Type 28. Wheel, Depressed Center (Saucer Shaped Grinding Face)

{ u e W \ q W \ b Y Z Y U U e [ l Y \ b V ` W Z j ` ` V c Y X ` l

U
Z j  ( 6 

Table 1b. Standard Shapes and Metric Size Ranges of Grinding Wheels ANSI B74.2-1982

Type 1. Straight Wheel

Type 2. Cylindrical Wheela

Table 1b. (Continued) Standard Shapes and Metric Size Ranges of Grinding Wheels ANSI B74.2-1982

D Type 5. Wheel,

Type 6. Straight-Cup Wheela

Type 7. Wheel, recessed two sidesa

Type 11. Flaring-Cup Wheela

Type 12. Dish Wheela

Type 27 and 27A. Wheel,

Table 1a

Table 2. Standard Shapes of Grinding Wheel Faces ANSI B74.2-1982

constructional steels.
 
      !    
         
      
     
        

"

&

&

'

Table 5
  

Table 6

Table 5
)   

Table 6

 

        

Table 3. Classification of Tool Steels by their Relative Grindability

1 2 3 4 3 5 6 6 7 8 9 :

GROUP 1Any area of work surface

<

>

<

>

<

>

E 3 4 F C C C C C @

<

>

<

<

<

<

>

<

<

J A

>

GROUP 2Small area of work surface

E

C @

C A

<

>

>

<

>

>

>

>

>

as found in tools
G

>

>

<

<

<

>

<

E 3 4 F 9 9 9 9 9 9

<

>

<

>

>

<

GROUP 3Small area of work surface

E

as found in tools
G J 4

N A

N B

N @

N A

N @

N @

N @ A

<

>

N @

N A

>

>

>

E 3 4 F 4

<

<

<

GROUP 4Large area of work surface (as found in dies)

N 5 4 5 3 5 > I

E 3 4 F 4

<

<

>

GROUP 5Any area of work surface

N @

E 3 4 F

<

<

Table 4. Grinding Wheel Recommendations for Hardened Tool Steels According to their Grindability
S S \ X T ] W ^ d W T c V e f X W b S g S b X Y i e f X W b S Q R S T U V W X Y Z _ [ W U ^ S V S T ` g R S b W h W b [ U V W X Y c g R S b W h W b U V [ W X Y c

{ c c T W

~  h X U x

{ c

{ Z S V g d p q | e s g d p q | e q s Z V X y S V g d p o e s g d p o e q s

{ x x

{ _ T v d p | e s g d p | e s V X y _ T v d p q | e r s d p q | e w l t s u

{ x x

{ c c T W

~  h X U x

{ c

Table 4. (Continued) Grinding Wheel Recommendations for Hardened Tool Steels According to their Grindability
S S \ X T ] W ^ d W T c V e f X W b S g S b X Y i e f X W b S Q R S T U V W X Y Z _ [ W U ^ S V S T ` g R S b W h W b [ U V W X Y c g R S b W h W b U V [ W X Y c

{ Z S V d p | e s g d p | e s Z V X y S V d p q | e r s g d p q | e s

{ x x

{ _ T v d p | e r s g d p | e s V X y _ T v d p q | e a r s d p q | e j l t s u

{ x x

{ c c T W

~  h X U x

{ c

Table 4. (Continued) Grinding Wheel Recommendations for Hardened Tool Steels According to their Grindability
S S \ X T ] W ^ d W T c V e f X W b S g S b X Y i e f X W b S Q R S T U V W X Y Z _ [ W U ^ S V S T ` g R S b W h W b [ U V W X Y c g R S b W h W b U V [ W X Y c

{ Z S V d p r | e q s g d p r | e q s Z V X y S V d p | e s g d p | e s

{ x x

{ _ T v d p r | e r s g d p r | e s V X y _ T v d p | e a r s g d p | e j l t s u

{ x x

{ c

{ c T W ^

~  h X U

{ d

{ Z S V d p r | e s f r | e s Z V X y S V d p | e r s f | e s

{ x x

{ _ T v d p r | e r s f r | e s V X y _ T v d p | e a r s f | e a s

{ x x

Table 4. (Continued) Grinding Wheel Recommendations for Hardened Tool Steels According to their Grindability
S S \ d W T c V e g S b X Y i e W T i e X Z T [ ] W ^ f X W b S f X W b S f [ X W b S

{ T W ^

~  h X c R

{ Z S V d p | e r s f r | e s Z V X y S V d p r | e r s f | e s d p r | e w l t s u

{ x x

{ _ T v d p | e r s f r | e s V X y _ T v d p r | e a r s f | e a s d p r | e j l t s u

{ x x

Table 5. Grinding Wheel Recommendations for Constructional Steels (Soft)

j ` ` V [ e a W g T V Z ` e \ Y Z ` u e W \ q W \ b f W Y g ` Z ` e h r j [ W X ` T V V T e [ \ q v U ` e Y Z W [ \ i \ X j ` ] W e ] Z r j [ W X ` d [ e [ ] Z y U ` z j ` ` V

] ]

] ] e W

{ |

` Z ^ Z [ ` Z ^

Table 6. Grinding Wheel Recommendations for Constructional Steels (Hardened or Carburized)

u e W \ q W \ b j ` ` V [ e a W g T V Z ` e \ Y Z ` r j [ W X ` v U ` e Y Z W [ \ f W Y g ` Z ` e h i \ X j ` ] W e ] Z r j [ W X ` d [ e [ ] y U ` z p w m

e W

} Y

` Z ^ Z [ ` Z ^

f e y Z [ f e y

Cubic Boron Nitride (CBN) Grinding Wheels.

 
  
    !     
     
              
   
 0   
    
     # $      
    
       
 
   +    

"

  

&

1240
 
         

B
        

D
    


"

  

  

  

&

Variations from General Grinding Wheel Recommendations.

     
   
 
                 
            
 
  
 
         #        
  

"

&

&

Dressing and Truing Grinding Wheels.

   
  
             

   # # 
      
             
                 
 # $      
 

"

Table 1

Table 1. Tools and Methods for Grinding Wheel Dressing and Truing
9 9 4 7 7 7 L

E 2 4

Table 1. (Continued) Tools and Methods for Grinding Wheel Dressing and Truing
9 9 L

E 1

<

Table 1. (Continued) Tools and Methods for Grinding Wheel Dressing and Truing
9 9 7 5 L

>

>

5 :

E 2 5 4

Guidelines for Dressing and Truing with Single-Point Diamonds.

      
  

       
    
                      

    
          
         #       
       
      , 
  
 

Depth of Cut:
  +  
              

Diamond crossfeed rate:

 .               

&

"

"

"

Table 2

10 15 CL 10 15 CROSSFEED
1 8"

1 " 4

(3.1756.35 mm)

Table 2. Typical Diamond Truing and Crossfeeds

f T X c c h S S i R S T S S \ ] S x f T X c c h S S i R S T S S \ ] S x Z [ Z [ j T U W Y g W S W Y b ^ ^ j T U W Y g W S W Y b ^ ^

Example:
          

Coolant
  

The speed of the grinding wheel

)      
                    
 

 
  #

The initial approach of the diamond

  
   

             # %      
      


         

The general conditions

     
 0
             
  
 
          

&

Resetting of the diamond point.:

  
 
      

      
  

     
                
 
     

&

'

"

Size Selection Guide for Single-Point Truing Diamonds.

  

        "     
   
                 
           
     # &     
  
                        
 
   

"

"

Table 3
 
           

"

&

Table 3
 #

"

"

&

"

"

Table 3

"

Table 3. Recommended Minimum Sizes for Single-Point Truing Diamonds

U ^ R \ S c X h U j T W Y i W Y m S S \ _ W ^ S Y c W X Y c  W Y b S c _ W U ^ X Y i g W S a Y i S k ^ S T

Z y q

>

&

"

'

"

&

Diamond Wheels Diamond Wheels.

       
      
    

               $   
                 
 
    
    

Shapes of Diamond Wheels.

     
      
           
 
     #    !  
       #    

&

&

"

Table 2
     

"

Table 3
 
    

Table 4
   
  

Fig. 1

<

Basic Core Shape:

       
 
   #        

Diamond Cross-Section Shape:

    
     !  
      
       
 
 

Table 2
 
    

Diamond Section Location:

           
 
 
  
       

Table 3

      

Modification:

           
  #       
 

Table 4

Table 1. Diamond Wheel Core Shapes and Designations ANSI B74.3-1974

Table 2. Diamond Cross-sections and Designations ANSI B74.3-1974

Table 3. Designations for Location of Diamond Section on Diamond Wheel ANSI B74.3-1974
_ S c W m Y U V W X Y X U Y i X b U V W X Y _ S c b T W R V W X Y a \ \ k c V T U V W X Y

[ U

Table 3. (Continued) Designations for Location of Diamond Section on Diamond Wheel ANSI B74.3-1974
_ S c W m Y U V W X Y X U Y i X b U V W X Y _ S c b T W R V W X Y a \ \ k c V T U V W X Y

Composition of Diamond and Cubic Boron Nitride Wheels.

  
  & 
    $  & % # !                    
       # $
0        
   #

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Prefix:
   

Abrasive Type: Grain Size:

                 

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Grade:
   # 

Concentration:
        #

Bond:
    

Bond Modification:

       
    #

Abrasive Depth:

      
                   

Manufacturer's Identification Symbol:

Table 4. Designation Letters for Modifications of Diamond Wheels ANSI B74.3-1974

9 J 9 6 5

E 9 7 4 4

Exception:
F

The Selection of Diamond Wheels.

                              
#

Table 5. General Diamond Wheel Recommendations for Wheel Type and Abrasive Specification
U c W b v R W b U \ p R R \ W b U V W X Y c X T Q R S T U V W X Y S S \ v R S p T U c W x S g R S b W h W b U V W X Y

Rough:
g W Y m \ S u X W Y V X X \ c  X h h U Y i m T W Y i W Y m _ q p t f [

Finish:

Rough:
g W Y m \ S u X W Y V X X \ c  ^ U b W Y S m T X k Y i _ q p t w _ y t | e e z [

Finish:
_ l p l _ l | e ] l | | e

Rough:
g U T R S Y W Y m U Y i U b W Y m X h h _ l l s _ l | e ] l | | e z

Combination

Finish:
d \ k V W Y m _ l t p t

g U n g U T R S Y W Y m l t t

Rough:
g k T h U b S j T W Y i W Y m  X T W X Y V U \ c R W Y i \ S _ l p l _ t o | e u l | | e z [

Finish:
S T V W b U \ c R W Y i \ S _ t p t _ r | e ] e z

f v \ W Y i T W b U \ X T f S Y V S T V v R S j T W Y i W Y m l l

a Y V S T Y U \ j T W Y i W Y m _ l p l

g \ X V V W Y m U Y i f k V X h h _ l p l ]

U R R W Y m _ W c b

Rough:
w U Y i w X Y W Y m _ w l ` _ w t _ y t | e z

Finish:

   
  
         
 
       

   
           
                    
    
    
  

     

"

Table 5
$           

the dimensions of the wheel,

  
     
     
 

Table 5
    

"

"

Guidelines for the Handling and Operation of Diamond Wheels.

  
        
 
      
                  
  
       


   
   
       

Mounting of Diamond Wheels:

 
           
 
 # 
  #    
  #       
 

Truing and Dressing:

 

           
           
        #  

"

Speeds and Feeds in Diamond Grinding. Wheel Speeds:

 
     
     
          
     0             ,      

              
 
    

'

Work Speeds:
       0          #

Infeed per Pass:

    #               

"

 |

 |

 |

Grinding Wheel Safety Safety in Operating Grinding Wheels.


   
     
     
             
  
 
    
#  
 
                  0  !  
        
    
   

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Handling, Storage and Inspection.

                     +   

         #

&

Machine Conditions.
   

 
    
 
     
   
    



&

Grinding Wheel Mounting.

 +             
               
     
        # #        

"

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Safe Operating Speeds.

               .    
   .      
    & 
           

&

Table 1
 

        

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D
! ! ! !

D
! ! ! ! ! ! ! ! ! ! ! ! ! !

  

Table 2
        


Special Speeds:
  
   
         
   
 # $   
  

&

Portable Grinders.
  
     
 
            
      
 & 
   

Table 1. Maximum Peripheral Speeds for Grinding Wheels Based on ANSI B7.11988
Y W g g v U ` e Y Z W \ b ^ U ` ` q ] f ` U ` \ q W \ b [ \ ^ Z e ` \ b Z j [ c [ \ q i \ [ e b Y \ W X [ \ q ] v e b Y \ W X [ \ q ]

Tables 1a
7 < ? =

1b
5

1220

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Table 2. Revolutions per Minute for Various Grinding Speeds and Wheel Diameters (Based on ANSI B7.1-1988)

Machinery's Handbook 29th Edition

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Cylindrical Grinding
                  ! "    # ! "  !  !      # ! $   $ % &    $ ' "       ( ! # ) $  " # )  # )  & ! # ) !  $ ( ( $   )     # !   " #   $ %  $ #  #   # ) ! * $  + ,  !  !   $ '    %  !    " * )   !      

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Size Range of Workpieces and Machines:

# '  ! $ % (     # '  ! ,   # " 2 " '  )  "   " #  ' ( !  #        $     (     $   " * !  )   " ! & !      (   )   ! " $ % (      % % !  !  # #  , ! " 2 !   ) 

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Plain, Universal, and Limited-Purpose Cylindrical Grinding Machines.

                 (   )   !  "  $  "   !  !  # ) ! 0  "   #  , ! $ % # )  " !  !      # ! ' " !  % $        ,   # " *  # )            $  "   ) #   #  , !  !  % $  ( . / ) ! '   & !  "                  !     0 ! ' " !  2       #  $  # $       # ) ! 0  "   

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Traverse or Plunge Grinding.

* $  + , !  % $  ( "   !   ,  $   #   ( $  $ #  #   * $  + ,  !  !   $  # ) ! %   ! $ # ) ! * ) ! !  "    !   &    ! " % $  # ) ! 

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Work Holding on Cylindrical Grinding Machines.

 $   # !     ) !     # ) ! (   )   !  '    # ) !       ,  $  $ % # ) ! ,   # # )  #    0 !    , # !  % $                      # ) !  $ '   " '  %   ! . / ) ! ( ! # ) $  $ % * $  + ) $       " $  % % !

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Table 1
# )  #   ! ( $

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Table 1. Work-Holding Methods and Devices for Cylindrical Grinding

H I J K L M N O K P M H I J Q R K S O K P M H K J Q T J J K P M U Y I M O I R J V M P M R P O N O K M L ` I N J O P Q a \ K O ] M P M R P O N O K M L J S K M Y _ I ] P _ Y J g ] I J K h S _ I J O h I O ] P Y P f ] P _ Y K M L O ] I \ P R a

Y I N

[ V \ K O ]

Y R K ^ I O ] I Q I M O I R b c R P T M

Y O ] I J S K M

Y _ I V N M K M

Y I d

i I O \ I I M O \ P P S S P J K O I Q I M O I R J K J N _ J P O ] I

Y S _ N O I S I M I M O _ e J T S S P R O I

Y J _ I I ^ I Q N R R K I J O ] I S P O I M O K N _ _ e h P J O N Q Q T R N O I V N J _ P M L N J Q P R d

Y R K ^ I S _ N O I f P R R P O N O K M L O ] I \ P R a b g N K _ J O P Q a R I Q O _ e S R I S N R I

Y N M

Y _ P Q N O I

Y Q I M O I R ] P _ I J

Y f P R P S S P J K O I Q I M O I R b N R I T J I K M O ] I \ P R a b

Y I M O I R J V R K ^ K M L P R

Y ] I _

i I O \ I I M O \ P Q I M O I R J P

i O N K M J K O J k _ K h K M N O I J O ] I

Y R N \

i N Q a P f O ] I Q P h h P M

Y O e S I j R P O N O K P M f R P h O ] I Q P M Q T R R I M O _ e N S S _ K I Q I M O I R d O e S I L R K M

Y K M L \ K O ]

Y R K ^ I R S _ N O I V

Y R K ^ I

i e O ] I _ K ^ I ] I N

Y J O P Q a J S K M

Y _ I N M

Y \ ] K Q ] R I l T K R I J N

Y P L N O O N Q ] I

Y O P O ] I

Y _ K ^ I O N K _ J O P Q a J S K M _ I b \ P R a S K I Q I b H R K ^ I M J S K M

Y _ I J S I R h K O O ] I

Y L R K M K M L P f O ] I \ P R a T S O P

i P O ] I M

Y J b

Y ] T Q a V L I N R I V P R Q N h d g \ P V O ] R I I V P R f P T R m N \ J h P ^ I

Y R N

Y K N _ _ e c

Y N S O N

i _ I O P \ P R a S K I Q I J P f

Y K f f I R I M O Q P M d

Y N Q O T N O I O ] R P T L ] h I Q ] N M K Q N _ I _ I h I M O J V ] N M

Y d V P R f K L T R N O K P M J N M

Y \ K O ] K M N L I M I R N _ _ e \ K

Y I

Y S P \ I R d P S I R N O I V I n I R O Q P M Q I M O R K Q N _ _ e N Q O d Q N S N Q K O e P f O ] I Q ] T Q a b o _ I n K

i _ I K M T J I J

Y K M L Q _ N h S K M L f P R Q I P M O ] I \ P R a S K I Q I b O ] N O V ] P \ I ^ I R V P M P O K M Q _ T

Y I ] K L ] d S R I Q K d

Y ] T Q a V K N S ] R N L h o P R Q I N S S _ K I

i e ] N M

Y P R S P \ I R P f N f _ I n K

i _ I p N S K

Y N Q O K P M N M

Y f _ I n K

i _ I N

Y N S O N O K P M O P

Y K f d

Y K N S ] R N L h Q N T J I J O ] I N O O N Q ] I

Y m N \ J O P f I R I M O \ P R a Q P M f K L T R N O K P M J

i e h I N M J P f

Y I f _ I Q O O I h S P R N R K _ e f P R N Q Q I S O K M L O ] I J S I Q K N _ m N \ J P f f I R ^ N R K I

Y T J I J f P R O ] I

Y \ P R a V \ ] K Q ] K J ] I _ \ ] I M f P R Q I K J L R K M

Y K M L P f

Y K J a d J ] N S I

Y N M

Y J K h K _ N R S N R O J b

Y R I _ I N J I b

Y P _ _ I O J ` P _ K M L

Y I ^ K Q I J \ K O ] I n O I R M N _ _ e P R K M O I R d q K h K O I

Y O P S N R O J \ K O ] S R I ^ K P T J _ e h N Q ] K M I

Y M N _ _ e N Q O K M L Q _ N h S K M L f P R Q I V I N J K _ e N N S O d P R L R P T M

Y ] P _

Y K M L J T R f N Q I J V

i I Q N T J I P f O ] I

i N _ I O P S P \ I R N Q O T N O K P M V N J J T R K M L ] K L ] J h N _ _ R N M L I P f Q _ N h S K M L h P ^ I h I M O P f O ] I

Y o N Q I S _ N O I ` N J f P T R K M I S I M

Y I M O _ e N Q O T N O I

Y m N \ J V N M e r J I

Y f P R ] P _

Y K M L

i T _ a e S N R O J V P R O ] P J I P f

i P R J I ^ I R N _ P f \ ] K Q ] h N e I T J I

Y V P R N \ a \ N R

Y J ] N S I V \ ] K Q ] N R I L R P T M

Y K M

Y I M O K R I _ e R I h P ^ I V T J K M L O ] I

i N J I S _ N O I f P R J h N _ _ l T N M O K O K I J M P O \ N R R N M O K M L J S I Q K N _

Y s N L M I O K Q S _ N O I o _ N O S _ N O I J V \ K O ] S P _ I K J O R K

i T O K P M N

Y N S O I

Y O P c S S _ K Q N

i _ I f P R _ K L ] O Q T O J J T Q ] N J N R I f R I d

Y O ] I \ P R a V N R I h P T M O I P M O ] I J S K M

Y _ I _ K a I l T I M O K M O P P _ h N a K M L V \ ] I R I O ] I R N S K

Y Q ] T Q a J N M h N e

i I T J I

Y f P R \ P R a \ K O ] O ] I Q _ N h S K M L N Q O K P M N M

Y I N J e N Q Q I J J O P

i P O ]

Y _ P Q N O K M L f N Q I M P R h N _ O P O ] I N n K J b O ] I t b H b N M O ] I I n S P J I

Y f N Q I N R I J P h I d

Y O K h I J P f N ^ N M O N L I b

Y O I N e R I J O J g \ P

i N J K Q O e S I J N R I T J I

W N

[ O ] I O \ P d m N \ c Q P h S _ I h I M O N R e \ P R a d ] P _

Y K M L

Y I ^ K Q I V

i O e S I J T S S P R O K M L O ] I \ P R a f R P h O ] I N Q a T J I

Y K M Q P M m T M Q O K P M \ K O ] S R K h N R e \ P R a

i N Q a R I J O

[ V _ I N ^ K M L N Q Q I J J

i e O ] I \ ] I I _ w ] P _

Y I R J V O P S R P ^ K

Y I N

Y K O K P M N _ J T S S P R O V

[ O ] I O ] R I I d m N \ O e S I

W Q I M O I R R I J O

[ b S N R O K Q T _ N R _ e O P _ P M L N M

x P R J _ I M

Y I R S N R O J b

Y K M L _ I d S T R S P J I I ^ K Q I J V

Y I J K L M I

Y f P R N S N R d g e S K Q N _ \ P R a S K I Q I J R I l T K R K M L J S I Q K N _ f K n O T R d

Y O K Q T _ N R \ P R a S K I Q I V S R K h N R K _ e f P R S R P ^ K d K M L N R I V N J I n N h S _ I J V Q R N M a J ] N f O J \ ] I R I

Y K M L J S I Q K N _ _ P Q N O K M L I _ I h I M O J b O ] I ] P _ K M L K J Q P h

i K M I

Y \ K O ]

i N _ N M Q K M L

Y f T M Q O K P M J w P R K M O I R M N _ L I N R J _ P Q N O I P M O ] I

Y S K O Q ] Q K R Q _ I P f O ] I O I I O ] f P R t b H b L R K M K M L b

Selection of Grinding Wheels for Cylindrical Grinding.

% $          !  !    2 # ) ! ,   (    %   # $  # $ 0 !  $  "   !  !    (  # !     . F # ) !  %   # $  "   ! # ) !  ( $ '  # $ % !  ! " " " # $  +     # " % ! !  " C 2 # ) !  ! "   !     '        " '  %   ! %    " ) 2 # ) !   #  $ $ % * )

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Table 2
%    #  $  " * ' !  #   . / )         

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Table 2. Wheel Recommendations for Cylindrical Grinding

s N O I R K N _ ] I I _ s N R a K M L s N O I R K N _ ] I I _ s N R a K M L j j c _ T h K M T h u o c d o P R L K M L J c d s

W c R h N O T R I J _ N h K M N O I

W o c d N L I J S _ T L

W c n _ I J N T O P R N K _ \ N e

[ c d s I M I R N _ d S T R S P J I L R K M

Y K M L

i R P M I T M N R R I _ J

Y S P O O K M L N M t b H b o c d s

Y ` N R c d s K O R N _ _ P e

W T J ] K M L J ] N R

Y I M I

Y J O I I _

[ o c d q I f P R I M K O R K

Y K M L c d

W T J ] K M L J Q N J O K R P M

Y d c f O I R M K O R K K M L

i N h _ P I J

W Q N J O N _ _ P e

i N h _ P I J

W ] N R

Y I M I

Y J O I I _

[ K J O P M J

W N _ T h K M T h

W p P T L ] K M L o c d q Q N J O K R P M

i d p T

i I R

Y o c d ` N R

Y S R N e I h I O N _

W P h h T O N O P R J Q P S S I R

W R N M a J ] N f O J N K R S _ N M I

Y K M J o c d K M b K N b N M

Y J h N _ _ I R

Y I N R K M L J c d q P ^ I R K M K N b

W R N M a J ] N f O J N T O P h P O K ^ I ` N R

Y I M I

Y S K M J N M

i I N R K M L J

[ K M b

Y K N b N M

Y J h N _ _ I R

Y o K M K J ] K M L c d P ^ I R K M b K N b

Y p I L R K M K M L c d s

Y p I L R K M K M L V J S R N e I

Y g K O N M K T h

W d N _ ^ I J O I h J N T O P h N O K ^ I

[ o c d

Note:
~

Operational Data for Cylindrical Grinding.

$ # ) !  ( ! #    ' # #   ,  $  ! " " ! " 2 # ) !  , ,   !  " , ! !     #  $     $    #  $  "  " * !    " # $ # ) ! $ 0 6 !  #  & ! " $ % %  $ ( $ # ) !  #  , ! " $ % ( ! #    ' # #   ( ! # ) $  "    !  

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grinding data,
! * $  + C 4 # ) !   % ! !  !       C 4   $ & ! ( !  # G ! ,  !

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Table 3
g R N ^ I R J I

Table 3. Basic Process Data for Cylindrical Grinding

Y R K M K M L g R N ^ I R J I f P R k N Q ] P R a Y M f I I S I R N J J P R a p I ^ P _ T j O K P M V

Y S I I V K M Q ] h h O ] I ] I I _ K

Y O ]

Y P M K O K P M f S h h

x h K M p P T L ] o K M K J ] p P T L ] o K M K J ] p P T L ] o K M K J ]

Y c M M I N _ I

i N R P M

Y ` N R I M I

Y b b

Y c M M I N _ I

Y ` N R I M I

Y b b

Y c M M I N _ I b b h N n b b b

h N n b

Y ` N R I M I

Y b b

Y c M M I N _ I

Y P _

h N n b

Y P _ H R N \ M

h N n b

Y g R I N O I

Y _ T M L I R K M K M L V M f I I

Y S I R p I ^ P _ T O K P M P f O ] I P R a

i _ N K M Q N R P M J O I I _ V ] N R

Y I M I

Y b b b b

Y c _ _ P e N M O P P _ J O I I _ V ] N R

Y I M I

Y b b b

High-Speed Cylindrical Grinding.

 ! '                      " !  !    ( $    ' " !        * ) ! !  "    (   )   !  !  #   2 ! % % $  # " * !  ! (   ! # $    " !

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CAUTION:
" '  )  " !  !  

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Areas and Degrees of Automation in Cylindrical Grinding.

* $  +  $ #  #  $     % $  # ) !  !   ,  $   #   #  0  ! #   & !  " !   ! % '    ( !  # " # )  # 2 $   ! " ! # % $    !  #      # ! 2 *    % '   #  $  *  # ) $ ' #  ! 1 '   < $         ! ( $ &   # ) ! * $  + 2 " #   #      " # $ , ,   # ) ! (    (

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Infeed,
2 % $   $ * ! # ) !  '   C

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Automatic cycling
   5 %  '   " ' , ,   2   #  $  2 # ) ! " '   ! " "  & ,   .

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Table traverse dwells

" " '  ! '   % $  ( ! , $ " '  C 2  $ ( 0   !  *  # )  , ,  $ ,

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Mechanized work loading,

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Size control
! *     $  #  $  " 0    6 ' " #  

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Automatic wheel dressing

   # ) !   % ! !  ( $ & ! ( !  # . C

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Numerical control
" (    5 $  ( !   ' ( 5 "  !  !  #  !  # ) "       " !  #  $  "    $  " !  ' #

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Cylindrical Grinding Troubles and Their Correction.

# !  !                     (   0 !    " "  %  !   " * $  +  ! % !  # "    #  )   2         '     ! " C 2  ( ,  $ , !    $ , !   #   (   )      * ) ! !   ! % !  # " G # $ $ )    $  " $ % #   #  $  2  $     2   8  

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Chatter:
$ ' # $ %  $ '  C  ( ,  $ , ! (  # # !  # $ (

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Faulty coolant:
# '  ! . ) $ ' #  $ $    # # $  ! (

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Wheel out of balance:

$ & ! ! !  %  $ (   ' "    %   " ! ) # !  %  # " " ,     ! .

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Wheel out of round: Wheel too hard:

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Wheel Defects
* ) ! !  . # ( ' " #  >

Improper dressing:
 )   !  ! " "  & !   .  )  !    ! % '    . " ! ,  $ , !

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Faulty work support or rotation:

    ! "    ! '  ! " ,     !  " #  ) # . 9  + !  !  #    # !  '  !   # !

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Improper operation: Faulty traverse: Uneven Traverse or Infeed of Wheel Head Work vibration: Outside vibration transmitted to machine:
$ % * ) ! !  % ! !  . ; ! ! !  '  ! * $  + " , ! !  .  ) !  + * $  + ,  !  ! % $  0      ) !  +    (  + ! " '   # #   " $      $  % $ '    #  $  . " $   # ! (   )   ! $  % $ '    #  $  . >

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Interference: Wheel base:

 5 " !  #  $  $  ( $  " .  ) !  + * ) !

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Headstock:
$  + " , ! !  " . $ $ " ! .  ) !  + .

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Spirals on Work (traverse lines with same lead on work as rate of traverse):
" ,     "     '  ! A B C (   )   ! ,   # " $ ' # $ %    ! 4    D C #  '   . ; ' ! " # !  ,  $  !  '  ! " % $   $   !  #  $  $ % # ) ! " ! #  $ ' 0  ! "   ! A

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Machine parts out of line:

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Truing:
! !  !  ! " .

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Check Marks on Work:

D C  ( ,  $ , !  ) !  # #  !  # ( !  C  ( ,  $ , !    ! " "   .

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Improper operation:
* $  + . " !  !  # !  & $    $ %  $ $    #  $ 8 8  ! "

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Wheel Defects
! ! & !  %  $ * .  ) !   !    $ $    #  # #  ! "   ) !  # 5 #  !  # 

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Improper heat treatment: Improper size control:

9 # )  # # ) !    ! (    #    !  .

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Improper wheel:
#  , ! $ %  0   "  & ! . 7 C  !  " ! " , ! !  $ % # ) !

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Improper dressing:
  ! "

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Burning and Discoloration of Work:

$ , !   #  $  2     ( ,  $ , !  * ) ! !  . ; ' ! " # !  ,  $  !  '  ! " % $   $   !  #  $  $

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Improper operation:
! !  . C

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Improper wheel:
 # !  & $  ' ( ! $ %  $ $ 

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Wheel Defects
! * ) ! !  . " ! 

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Isolated Deep Marks on Work:

* ) ! !      $  "   !    )   !    0

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Fine Spiral or Thread on Work:

D C %  '  #  * ) ! !    ! " "   . ; ' ! " # !  ,  $  !  '  ! " % $   $   !  #  $

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Improper operation:
)  ! " , !  # # $ * $  +  $ #  #  $ !  $ ' " ,  " " ! " . ?  ! & !  # $  + .

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Faulty wheel dressing:

#  !  ! ! "  $ *     ! # $ $  ! ! ,   ' # . $ '   $

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Narrow and Deep Regular Marks on Work:

 $   " ! . " ! %   !      "  8 ! .

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Wide, Irregular Marks of Varying Depth on Work: Wheel Defects Widely Spaced Spots on Work:
" !  )    !     ! * ) ! !  . ; ! ! . ; $ '   ! " $ % #  $ ' 0  !    ! .      !    #  ' ! * ) ! !  . ! ! , $   %  $ ( * ) ! !  % 

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Irregular Fish-tail Marks of Various Lengths and Widths on Work:

 "    #   $ $    # .   !   #   + %  ! 1 ' !  #   . " ! %   # !  % $  %   ! %    " )     '    "  % # !    ! " "   $  * ) !   )     # $ %   !  * ) ! !  .

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Wavy Traverse Lines on Work:

 $ $ " ! # )  ' " # $  " ,     !     $   !    ' "

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Irregular Marks on Work: Deep, Irregular Marks on Work:

(  + ! " '  ! 0  $ # # !  "   ! ' " !  .

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Isolated Deep Marks on Work:

" #  $  4 D C  $   " !     " $  % $  !   ! " , !  #  & ! " ' ! " # !  ,  $  !  '  !

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Grain Marks on Work:

$ %  $ ' )      %    " )   # $ $  $   " ! $  # $ $ " $ % # .

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Inaccuracies in Work:
; $ '   ! " $ % #  $ ' 0  !   ! A $ , !   #  $  4 C  $ $    # 4 C

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Misalignment of machine parts:

, !     ( ,   .

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Work centers:
# !  "   !       '  !      #  ) #    + 5  !  # !  ) $  ! " .

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Improper operation:
" " '  ! " $ * $  + * $  : # " , ! !    # )    !  . 7   $ * *

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Coolant: Wheel: Improper dressing:

! 0      ! *    .

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Spindle bearings: Work:

@ $  + ( ' " #

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Inaccurate Work Sizing (when wheel is fed to same position, it grinds one piece to correct size, another oversize, and still another undersize):
; $ '   ! " $ % #  $ ' 0  !   ! A B C  ( ,  $ , !  * $  + " ' , , $  # $   $ #  #  $  4 D C * ) ! !  $ ' # $ % 0      ! 4 C  $   !  * ) ! !  4 C  ( ,  $ , !    % ! !  4 C  ( ,  $ , !  #   & !  " ! 4 C  $ $    # 4 C (  "     ( !  # 4    C * $  + .

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Improper work support or rotation:

 + 5  !  # !  #  , " # $ ,  $ , !     ! . ! " '  " 2 ,  $ , !    " ,   !  .

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Wheel out of balance: Loaded wheel: Wheel Defects Improper infeed:

; ! !  ) !  + % $  *    "  #  $  $ % * ) ! !  0  " ! 0  ( !   " $ % # ) !   6 ' " # ( !  #    # ) !  0     # % $  *   5 ' , ,   # " .  ) !  + * ) ! !  " ,     ! 0 ! 

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Improper traverse:
# !  ! " "  & !  ' 0     #  $  %       ! #   & !  " ! ,  .  )   !  !  # ) $ % # 

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Coolant: Misalignment: Work: Uneven Traverse or Infeed of Wheel Head:

C " !  !  # !  & $  ' ( ! $ %   !    $ C  ) !  +  ! & !         ( !  C @ $  + ,  !  ! " (   &    # $ $ ( '  )   ) ! !  ) !     ! A       !    * ) ! !  ) !   2 )   #  $  " 2    * ) ! !  $ ' # $ % 0      ! . ; ' ! " # !  ! A

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Carriage and wheel head:

)  ' 0     #  $     )     '    " $   %   ( .  ) !  +  ' 0     #  $  $    !    +   !      ! . ?  ! & !  #

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Hydraulic systems:
& ! " % $  $    !  +  !   $  " # )  # , !  (  #  !  + 

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Interference: Unbalanced conditions:

9  + ! " '  ! & !  0 !  # " 2 $  )  ) " ,     ! +   

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Wheel out of balance: Wheel Defects: wheel is acting too hard,

@ ) !   + $ %  ' # 2  )  # # !  2    0 '     $ % * $  +  ! " '  # .

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wheel is acting too soft,

  $ # 5 ) $     5  ' #  ! " '  # . ! " # !  ,  $  !  '  ! " % $   $   ! 

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Wheel Loading and Glazing:

B C   $   !  # * ) ! !  4 D C  ( ,  $ , !  > C ' ( (   $ $    # .

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Incorrect wheel: Improper dressing:

" %  " # !    ! " "   #   & ! 

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Faulty operation:
 ! & !  #  $     4 ( $

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Faulty coolant: Gummy coolant:

! $   "  % *  # !   " )  " $ % # !  !  " ) $ '   0 ; '

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Wheel Breakage:
( $  ! ,  !  ! "   ! A B C !    2 ' " ! 0  $ # # !  " 2 #  %    !    * ) ! !  4

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Centerless Grinding
  !  # !   ! " "       # ) ! * $  +  " " ' , , $  # !  $   * $  +  ! " # 0    !     " 0 ! # * ! !  # ) ! >       * ) ! !       ! '   #   * ) ! !  . / ) !  ! '   #   * ) ! !  !  !       "   ' 0 0 !  0 $   ! 

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Through-feed Method of Grinding.

           ,   # " . / ) ! * $  +  "  & !     0 ! # * ! !  # ) !           ! '   #   * )  ! , !   " ' , $  # ) !    ( ! # !     " , ! !  $ %

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In-feed Method of Centerless Grinding.

,   #    !  # )   # ) !  $ '      ( ! # !  2 # ) !   5 % !  " "  (     # $ ,  '  !  ' # % $  (       $    # $ 0 !  $ '        $  ! $ , !   #  $    !   (  # !  0

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End-feed Method of Grinding.

/ ) !       * ) ! !  2  ! '   #   * ) ! !   ) $ # ) !     # ) ! * $  +  " % !    %  " # $ , . =  # ) !  # ) !       $   ! '   #  

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Automatic Centerless Grinding.

 ' # $ (  #       0  ! 1 '  , ,   # ) ! (   ) ,  $ &   !  # ) ! " )  , ! $ % # ) ! ,   # *    , ! 

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Internal Centerless Grinding.

,      ,  ! ' #    8 ! # ) ! $ ' # "   !    ( ! #  $   !  #    *  # ) # ) ! $ ' # !  " '  %   ! . > 0     ) $  ! "    0 !  $ '   0  # ) !

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Centerless Grinding Troubles.

 $ ( ,   !  0   (   ' %   # '  !    !   "  !  # !   ! " "       .

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Chattermarks
 !  # !  " $ % # ) !   ' "   # $ $ " # ! ! ,  ,      # ) ! " ! # 5

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Feed lines or spiral marks

# ) ! !  # "   ! $ % # ) !       * # $  "   ) # #  , !   0 $ ' #

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Scored work
$  % ' " !  # $ # ) ! *  # )     !  " !  0 ! ' " !  .

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Work not ground round

   ! 6 $     # ) !  !  # !  " $ )  ) !     ' "    " $ % # ! 

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Work not ground straight

# ) ! '   ! " ' " !      #  $  '   $ %  $  & ! $   $    & ! %   ! " $ # ) ! %  $  # !   2 # ) ! * $  + '   !

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Difficulties in sizing
( !  )    " (    (   0

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Flat spots
   !  !     , $ * !  0 ! # * ! # ) ! * $  +  ! "

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Surface Grinding
/ ) ! # !  ( " '  %   !        ( ,   ! " 2    '   !  # # !  )      ' "  ! 2 # ) !       $ % " '  %   ! " * )   )   ! ! " " !  #      %   # . ; ! & !    ( ! # ) $  " $ % " '  %   !       2 ) $ * ! & !  2   !    , # !     ' " !  # $ ,  $  '  ! " '  %   ! "  )     # !   8 !  0  ,      !  " #    ) #    ! !  ! ( !  # "   $  !    !  #  $  2

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Advantages of Surface Grinding.

"  (     # $ # ) $ " ! ,  $  '  !  0  " '  %   !  !  ! ! 2 ,      . ; '  %   !       2 ) $ * $  " # )  #   !      !  $ ' # *  # ) ( ! #   5  ' # # 

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Principal Systems of Surface Grinding.

" '  %   ! , $  #  $  " $ % # ) ! * ) ! !  2 0    % % !  !  #    0    % % !  !  #   # !   !   # !  ( $ & ! ( !  # " . / ) ! &   ! " , !  #  & !   ,  0    #  ! " 2    0 ! " # 0 !  ! &  ! * !

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The operating surface of the grinding wheel,

"   ! C 4

The movement of the work during the process,

 #   C $   $ #    G  $  #   ' $ ' " C 2  ! , !     $  # ) ! !     !  " .

&

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Table 1
  "  " # ! ( "     !  "   !   # ! $   ! " .

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Operating Surface, Periphery of Wheel: Movement of Work, Reciprocating:

( $ '  # !  $  # ) ! ) $   8 $  #   (   )   ! #  0  ! # )  #  " #   & !  " !      !   ,  $   #   ( $ " , ! !  !  !      " !  !  # !  %  $ (  " # ! ,  ! " "   &     0  !    ! . / ) ! #    " & !  " ! (     !    $ " " % ! !  $ % # ) ! #  0  ! $  $ % # ) ! * ) ! !  "    ! 2 $ , !   # ! "  # # ) ! !   $ % # ) !  !

"

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Operating Surface, Periphery of Wheel: Movement of Work, Rotary:

' " '     $  # ) ! % '   5    ( ! # !  (   ! #    ) '  + $ % # ) !     '    (   )   ! #  ,  ! " ! #  $  " #   # $   ' # $ (  #       &      " , ! !  2 # ) !   # # !  (    #      ! 1 '   , !   , ) !    " , ! !  $ % # ) ! * $  + " '  %   !   !  0 !    $ '   . / ) ! * ) ! !

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Operating Surface, Face of Wheel: Movement of Work,Reciprocating:

"  (     # $ # ) !  !   ,  $   #   #  0  ! 5 #  , ! , !   , ) !    " '  %   !     !  2 0 ' #   %   ! 2 ' " '     *  # ) # ) !   ( $ %   ' , 5 " )  , !  * ) ! !  2 $   " ! ( !  #   * ) ! !  % $    ,  0  ! $ %  $ & !     ( '  ) *   !    !  $ % # ) ! * $  + " '  %   ! # )   # ) ! , !

"

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Operating Surface, Face of Wheel: Movement of Work, Rotary:

' " '     $ % " ! ( !  #   #  , ! 2  " " ! #    , $ "  #  $  # $  $ & !  !  # ) !       ' !   $ % # ) ! #  0  ! $  2 ( $  !  $ ( ( $    2 # $  !   ) 0 !  $   # ) ! #  0  !  !  # !  ! #    ) '  + !  !       $ & !  " # ) ! !  #   ! #  0  ! " '  %   !    %    

'

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Table 1. Principal Systems of Surface Grinding Diagrams

"

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Operating Surface, Face of Wheel: Movement of Work, Traverse Along Straight or Arcuate Path:
/ ) !       * ) ! !  2 ' " '     $ % " ! ( !  #   #  , ! 2  " " ! #    , $ "  #  $  # $  $ & !  !  # ) !       '      !   !   # ) ! , !   , ) !   $ % # ) ! #  0  ! $  2 ( $  !  $ ( ( $    2 # $  !   ) 0 !  $   # ) ! #  0  !  !  # !  . 7    !     '    (   ! #    ) '  + !  !       $ & !  " # ) ! !  #   ! #  0  ! " '  %   !    %      #  # ! " # ) ! ( $ '  #   $ % * $  + ,  !  ! " 2 ! & !  $ % %  # '  ! " 2 * ) !   ! !  !  . / ) ! '    # !  5

'

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Selection of Grinding Wheels for Surface Grinding.

       * ) ! !  % $  " '  %   !        " # $ 0  " ! # ) ! " !  !  #  $  & ! " # ) !       * ) ! !   !  $ ( ( !    #  $  " % $  /  , ! " B 2  !   ,  $   #       $ #    #  0  ! " '  %   !     !  " *  # ) ) $   8 $

"

"

Table 2a
' " !  $   & ! " # ) ! ! !  " 2   

"

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Table 2b
 ' , * )

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Tables 2a
  +   " *  # $ " ! ,  !  !   ) ! " , !     #

2b
$  # $ # ) !  ! $ % 0

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Table 2a. Grinding Wheel Recommendations for Surface Grinding Using Straight Wheel Types 1, 5, and 7
Y ` P R K P M O N _ d J S K M _ I V R I Q K S R P Q N O K M L d O N i _ I ` P R K P M O N _ d J S K M Y _ I V R P O N R e d O N i _ I Y J T R f N Q I L R K M I R J J T R f N Q I L R K M Y I R J

Y s N O I R K N _ j K M Q ] I J K N h I O I R

Y j K N h I O I R N M

Y P ^ I R ] I I _ J P f N M e

Y K N h I O I R

Y ` N R I M I

Y J O I I _ V

i R P N

Y Q P M O N Q O

Y ` N R I M I

Y J O I I _ V

Y R T S O I Q T O

Y I h I M O I Q N R

i K

Y I J H K N h P M Y \ ] I I _ J

Y H K N h P M \ ] I I _ J

Y H K N h P M \ ] I I _ J

Table 5

1245

Table 2b. Grinding Wheel Recommendations for Surface GrindingUsing Type 2 Cylinder Wheels, Type 6 Cup Wheels, and Wheel Segments
g e S I g e S I ] I I _ s N O I R K N _ U Y e _ K M I R ] I I _ J U T S ] I I _ J u I j L h I M O J j j

Y ` K L ] O I M J K _ I Q N J O K R P M N M M P M d

i P f O J O I I _ V h N _ _ I N _ I Q N J O K R P M V

i J O I I _ Q N J O K M L J V P K _ I R S _ N O I

Y ` N R I M I

Y J O I I _

i R P N

Y Q P M O N Q O

Y ` N R I M I

Y J O I I _ M N R R P \ Q P M O N Q O

Process Data for Surface Grinding.

#   ,  $  ! " " ! " 2 # ) ! " , ! !     % ! !    # ! " # )  $    #  $  "  " * !    " # $ # ) ! $ 0 6 !  #  & ! " $ % # #  , ! " $ % ( ! #    ' # #   ( ! # ) $  "    !  

"

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Table 3. Basic Process Data for Peripheral Surface Grinding on Reciprocating Table Surface Grinders
Y H P \ M f I I V U Y R P J J f I I K M b S I R S N J J i ] I I _ g N _ I S I R S N J J V

Y S I I V

Y S I I V o K M K J ] V f R N Q O K P M P f

Y s j N O I R K N _ ` N R M I J J

Y P M K O K P M f S h f S h p P T L ] h N n b \ ] I I _ \ K

Y O ]

Y p Q h N n b c M M I N _ I V Q P _

Y R N \ M d d b

i _ N K M Q N R P M

i N R T R K I

Y N M

x P R

Y l T I M Q ] I N M

Y O I h S I R I

Y c M M I N _ I P R

Y l T I M Q ] I N M

Y O I h S I R I

i N R T R K I

Y N M

x P R

Y l T I M Q ] I N M

Y O I h S I R I

Y d ] M c M M I N _ I d d b b

Y d p Q T I M Q ] I N M

Y O I h S I R I

Y d d b b

Y ] M P R h N _ K I V N M M I N _ I

Y d d b

Y K O R K K M L J O I I _ J

Y d p Q K O R K I

Y d d b

Y p Q h N n b P R h N _ K I V N M M I N _ I

Y d d b

i N R T R K I

Y N M

x P R

Y l T I M Q ] I N M

Y O I h S I R I

Y c J Q N J O V N M M I N _ I V N M

x P R

Y l T I M Q ] I N M

Y O I h S I R I

Y c J Q N J O V N M M I N _ I P R

Y l T I M Q ] I N M

Y O I h S I R I

Y ] M c M M I N _ I P R Q P _

Y R N \ M d d b b

Y t ^ I R ] M T I M Q ] I N M

Y O I h S I R I

Y d d b b

Y c _ T h K M T h c J Q N J O V Q P _

Y R N \ M

Y N _ _ P e J P R O R I N O I

 ! # ) !

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Table 3
" '  %   !

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Common Faults and Possible Causes in Surface Grinding.

, !  % $  (    ! *  # )  !    # $ 0 $ # ) # ) ! 1 '    #  $ % # ) !  $ '   " '  %   ! %   !       2  ! 1 '   ! " # ) ! ( $   # $    $ % # ) ! ,  $  ! " "    # ) !    & !  " ! # $ # ) !  # #    ( !  # $ % # )  # $   .

"

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Table 4
 ! # !  (    (    !  ! &

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Vitrified Grinding Wheels.

      * ) ! !  " . / ) ! 0 $          " # $ ! # ) !     " ' , , $  # " # )

&

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amount
 " ! #  ! (  $  #   $

"

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strength of
) !  &  !  # ) ! )    !  # ) !

bonding
* ) ! !  .

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Silicate Bonding Process.

"      # ! $ % " $   $  *  # !    " "    " $ " $ ( ! #  ( ! "  ! % !   !  # $  "  $ ( ,    #  & !     # #  ! ) !  # 2   

"

&

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semi-vitrified
% $        2 "      # ! * ) ! !  0 ! (   ! 0  # )  "

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Oilstones.
@  " )  #   "   "  #  " %   # $   % $ &      %  $ (

'

"

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"

Washita
!  !          $ ' "      # 2 # $ &  # 

Arkansas.
"   !  !  # ) ! ( $ % @  " )  #   $ ' " %    #    )

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  !

 $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

$ $ $ $ $ $ $ $ $ $ $ $ $ $ $

 #

" 

 $ $

 

 $   $ $ $

  $   $ $ $

Table 4. Common Faults and Possible Causes in Surface Grinding

 $ $ $ $ $

 

 !

$ 

    

 

$ $ $ $ $ $

Machinery's Handbook 29th Edition

" 

 

 

! $  $ $ $

 

 

 

  

 

 

  

 

! 

 

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Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Offhand Grinding
F % % )           $  "  " # " $ % ) $     # ) ! * ) ! !  # $ # ) ! * $  + $  # ) ! * $  + # $ # ) ! * ) ! !           # $ 0  $   # $  !     ! "        '  ! " " '  ) $ , !   #  $  "  "  !  #    #  , ! " $ % # $ $  " )   , !  5

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Floor- and Bench-Stand Grinding.

 $ ' 0  ! 5 !   %  $ $     0 !   ) " #    " .  >  ! ,    " ) $ , " 2 # ) ! " !     !  "   ! ' " '     , % $  (  "  !     ! $ ' "  $ ' )          

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Portable Grinding.
%  !  0  ! " )  % #     !  "   ( !   2 # ) $ " !    & !  0  #  0  !     !  "   ! ' " ! 

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Swing-Frame Grinding.
 ( $ '  # $ % (  # !      " # $ 0 !   ! ( $ & ! B #  ( ! "  " ( '  ) (  , $  #  0  !     !  " 4    #  ( !

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Abrasive Belt Grinding

7 0   "  & ! 0 !  # "   ! ' " !    # ) ! ( ! #   * $  +      ' " #   % $   ! ( $ &   " # $  + 2   ) #   !     ' , $ % ( ! #   " '  %   ! " 2       * !   " 2  ! 0 '     2 0  !  +      , $   " )   ) $  ! !  ! " 2   

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Table 1
* ) ! !  . / )   $  !    (  # !     C 2 #

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Table 2
 " $ % # ) ! ! )     ! "   # !   !

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Abrasive Cutting
7 0   "  & !  ' # 5 $ % % * ) ! !  "   ! ' " !  % $   ' # #   " # ! !  2 0   " "      ' (   ' ( 0   "    # ' 0 ! " $ %    " )  , ! "    )     ! " " ! " 2  !   (   " 2 ,   " #   " 2   " '   #   (  # !     " 2   " "     ! ( !  # !     5

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( % $

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N 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9

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Table 2. Guide to the Selection and Application of Contact Wheels

Y ` N R M I J J N M Y u T R f N Q I s N O I R K N _ H I M J K O e T R S P J I J ] I I _ c Q O K P M U P h h I M O J j

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Grading Diamond Dust.

  # !  0   ' ( 0 !  " 2 # ) ! %   !  ( $   2  % # !  0 !     ' " ) !  # $ $   & ! $   . / )  " (  # '  !  "   

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Cutting Properties of Laps and Abrasives.

#  ! " $ %  0   "  & ! " * ) !  ' " !  *  # )   % % !  !  #   , ,   *  "  $   '  # !  2 # ) !  ! " '  # " $ % * )   ) * !  !  & !   ,  ! " !  # !  0 ! % $  ! # ) ! 7 ( !      ; $   ! #  $ % 9 !  ) 

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Cutting Qualities with Different Laps.

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Wear of Laps.
   # ) !  0   "  & ! ' *  # ) ! ( !   2 * )   ! ! ( !   . F     & ! 

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Lapping Abrasives.
   0 $  '   ' ( ' " '     0 !  # "   # ! *  " 0 ! # # !  (    " #    ) #    ! . / ) !  )   !

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Effect of Different Lapping Lubricants.

# ! " # !  2 *  " % $ '   # $  ! , !   ' , $  # ) ! +    $ % 

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  # ! $ %  ' # #   2    # )  # 2  

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Gasoline and Kerosene:

   # " # ! " # !  .  $  "   !     # ) !   % % !  !  #   , " 2  "  " % $   $ $    ! 2  & ! " # ) ! 0 ! " #  ! " '  # "

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Turpentine and Alcohol:

     , . @  # ) ! ( !   2 # '  , !   " # 5   $     " # ! !    , " 2  # ! ( !   $  # ) !   " # 5   $    

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Soda Water:
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Lapping Pressures.
" 1 '   !    ) G B D + ?  C 2 ,  ! " " '  ! . / ) ! )  ) !  ,  !  $ # " $ ! % % !  #  & ! $  # ) ! 

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Wet and Dry Lapping.

$ % $       0   "  & ! $  # ) ! " ' # ) !  !  " ( $  ! $   ! " " ( $ & ! ( # ) !   ,  " %   " #  )   !  0   '

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Summary of Lapping Tests.

!  #  0   "  & ! " . / ) !  !  "  $   &   #  ' # #    " ,    #       ,  $ , $  #  $   ,  $ , $  #  $  " A   " #   $  2 B . 4 " # ! ! 

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CNC NUMERICAL CONTROL PROGRAMMING

Introduction
z ' ( !       $  #  $  ,  $   ( (   5 0 ! # # !  +  $ *   "  z  ,  $   ( (   5  "     # !    ,   # $ % # !  )  $  $  +  $ *   " z ' ( !       $  #  $  G z  C 2 $   # " ( $  !   ! 1 '  &   !  # 5  $ ( , ' # 5

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how to machine a part

 !  $   8 !     ! " #    #   2 ,  $  ! " " ! " 2     $       . = 1 '      ( , $  #   # " +    "

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CNC Coordinate Geometry

7 0  "   " # ! ,   '   !  " #       z  ,      ,  ! "  " # $ '   !  " #    # ) ! ! $ ( ! #   $ % (   )   ! # $ $  " . / )  " # !  (  $ & !  " # ) !  !   #  $  " )  , 0 ! # * ! !  # ) ! (   )   !   #  2 ,   #   #  2    # $ $    #  2

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origin
1 '   '   # ! G    # *

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rectangular coordinate system

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system Points
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Fig. 3

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CNC Programming Process

 z  ,  $   ( G   " $     ! 

part program
    !   "  $  "     &   !  "  % !    ! G ( ! # ) $  $ %   #  !

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Word Address Format.

#      , ' # % $  (  #     !   ,  $  !  % $  ( $ 0 !    " #    #  ' ( !        " #  '  #  $  "   ! 

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words
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character
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word
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unit of instruction block

2 * )   )  "  0  $  + " C   ! *   # # ! 

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Electronic Industry Association

  "    % '   #  $  " % $  ,   # ,  $   ( 0 ' # )  "  ! & !  % '    " '   ! !  !    &   $  ( !  # % $    % % !  !  #  $  #  $  "  " #

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Program Development.
# )  # *    !  !   # !  * $  +    C 9   '   ,  $   ( (   G  0 C  $ ( , ' # !  0  " !  ,  $   (

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Manual (G-code) Programming

# $ !   $  " . / ) ! ,  $   ( ( !  *   # ! " ! & $    $ ( , ' # !  # $ !  # !  ,  $   ( (    , $  + ! #     '   # $  .  " ,  # ! $ %  # "

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Computer Based Programming:

  , ' # 2    #  ,        ! 1 '   !  ! & !  $ %     !   # !  ! $ ( ! #   " !  & ! "  " # ) ,    ( ! # !  " . ; , !   %    # $ $   ! %    #

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Shop-floor Programming:
,  $   ( (   2  " , !  % $  ( !   *   ! 0 '   #   # $ # ) !  $  #  $  "  "   ( ( !  $ , !   # $    # !    #  & !

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Macro Programming:
#  ! 1 '   ! " # ) $  $ ' ) +  $ > ,  ! 2 # ) ! "    ! , '  , $ " ! $ % % $   ,   #   '    , '  , $ " ! . F

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1305 Control System.

" # ) ! (     $  ! $ %     # $ # ) ! (   )   ! $   #   '    #  , ! $ %  $ 

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ON / OFF switch: Cycle start: Emergency stop: Feedhold: Single block: Optional stop: Block skip: Dry run: Spindle override: Feed rate override: Chuck clamp: Table clamp: Coolant switch: Gear selection: Spindle rotation: Spindle orientation: Tool change: Reference position: Tailstock switch: Index table switch: M-S-T lock: Machine lock: Manual absolute: Z-axis neglect: MDI mode: AUTO mode: MEMORY mode: DNC mode: EDIT mode: MANUAL mode: HOME mode: HANDLE mode: JOG mode: RAPID mode: Memory access: Lube light: Error lights: Optional Stop and Block Skip:
? $ * !  " *  #  ; #   # " ,  $   ( ! ! ; # $ , "    (   / ! ( , $       " # $ , " ( 7   $ * " ,  $   ( / ! ( , $       " # $  $  ! " 0  $  + " ,  !  > =   0  ! " ,  $   ( # ! " # F & !     ! " ,  F & !     ! "  " ,    "  '   !  ; ) $ * "  '   !  # " #  $ $    #  $  #  $ ; ) $ * "  '   !  # ; ,     !  $ #  # 9   '   " , ; *  #  )    $ *   ; *  #  ) ! "  /    " # $  +    9   '       "  0  ! " (   )   !  "  0  ! "    (    $ $      # ! " 9     

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Manual Data Input (MDI):

   $ * " 1 '   + !  #   $ % ,  $   (    $ * " ,  $   (   #  # $ 0 ! !  # !  # !   $ ( ,  ! # ! (   )     ,  $

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CNC Program Data

/ ) ! ,  $   (   #   "   $   !  #  $  $ %    # ) ! ,  $   ( !  #   ! " # )  # *    0 !    ! , # !  0  # ) !  z  "  " # ! ( . 7  # ) $ ' ) # ) ! 0  "   ,  $   ( ,      ,  ! "   ! # ) ! "  ( ! 2 # ) !   # '   ( ! # ) $  " $ %

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Program Structure.
  ( # )  #  " * !    ! "   ! $  ,  , !  $   $ ( , ' # !  "  " ) $ '   0 !  $     4  ! , ! #  #

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Comments and Messages:

,  $   ( 2 ,  $ &   !  # ) !    ! !     ! $ %  $ ( ( !  # " (   " #      !   !  !   !  # *   # $   % $ 

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Program Number (O-address):

(   )   ! 2 0  # ) !  z  $ , !   # $  . F    ( ( !  2 #  ,       2 % $  " ' 0 ,  $    $ * !  0  % $ '  $  %  & !  ' ( !      

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"

>

"

'

"

"

"

'

'

"

"

Block Number (N-address):

,  $   ( " ! 1 ' !   ! G 0  $  + C . 7 0  $  + " % $   "  ( ,  ! (   )      $ ( ,  ! * $  + . / $   " #   '  " )

"

'

"

"

'

&

"

'

'

'

"

'

"

"

"

"

'

"

'

"

"

'

"

"

'

"

"

'

"

"

"

&

"

"

"

"

"

"

"

'

"

"

&

'

"

"

"

"

"

'

"

'

"

"

'

"

"

'

"

'

"

"

"

"

'

"

'

"

"

'

'

"

"

&

"

"

"

"

"

"

"

"

&

"

'

"

"

"

"

'

"

&

&

Preparatory Commands (G-address, G-codes):

+  $ *   " 5  $  ! " . / ) !     ! " "   !  #  %  ! "  ,  $    $ 0 6 !  #  & ! 5 # $ ,  ! " ! # $  # $ ,  ! ,   ! # ) !  $  #  $  " # $   !  #    ( $  ! $   " #  # ! $ % $ , !   #  $  . $  !  ( ,

"

"

"

"

"

"

"

"

"

"

"

"

"

"

"

preparatory command
 #     # !  ,  ! # # ) ! ,  $   (

"

"

"

'

"

"

"

'

'

"

&

"

"

'

"

'

"

'

"

&

'

'

"

"

'

"

"

&

'

"

"

"

'

modal
 )   !  # ) ! ( &     #

"

"

'

"

&

'

"

"

"

"

"

"

'

"

"

"

'

'

Table 1. Typical Turning G-codes

Table 2. Typical Milling G-codes

'

"

"

"

"

"

'

"

"

"

"

'

"

"

"

'

'

"

&

'

'

"

"

"

'

"

'

"

"

"

"

"

'

"

"

"

"

"

'

"

"

"

'

"

"

"

&

"

"

Miscellaneous Function (M-codes).

"

"

'

"

'

"

'

"

'

"

"

'

"

"

'

'

"

'

"

"

&

'

"

'

"

"

"

'

"

'

"

"

"

"

"

&

"

"

"

"

"

"

"

"

'

&

'

"

'

"

"

"

Table 3. M-codes
i i |
} } | 

Units of Measurement (G20, G21).

# )  #  $  #      $   #  $  2   " #    ! 2     ' " $ # ) !   #  & ! '   # " $ % ( !  " '  ! ( !  # . $ 

"

"

"

"

"

'

"

'

"

'

"

"

'

"

'

"

'

"

"

"

'

"

"

"

'

"

"

"

"

"

"

"

"

"

'

"

"

"

"

'

"

'

'

"

"

"

"

'

'

"

"

"

'

'

"

"

"

'

'

&

"

&

&

'

"

"

"

Absolute and Incremental Programming (G90, G91).

"

"

"

"

"

"

"

"

'

"

'

"

"

"

'

'

"

absolute
$  0  # ) !   ( (   (   ( . / ) ! "

"

"

incremental
% # ) !  0 " $  ' # !  )   !   # ) ! ! " . / ) ! (   

"

"

'

"

'

"

'

"

"

'

"

"

Spindle Function (S-address).

  ' " ! " # ) ! (   )   ! " ,     ! # $  $ #  # ,  $   ( (  0  !    !  " " ! # 0  # ) ! ( / ) ! (  6 $    % % !  !   ! 0 ! # * ! !  ( 

spindle
#   ! %   !  )   ! (       !  # !

'

"

"

&

'

"

'

"

'

'

"

&

'

"

"

"

"

"

"

'

"

"

"

"

'

&

'

"

"

"

"

'

"

"

'

"

"

"

'

"

"

'

"

'

"

Example:
; 9 ; 9

"

"

"

&

'

"

'

&

"

"

&

'

"

'

CNC Lathes:
 "  $ #  #       $ , !   #  $  " . / $ " 5  $  " #  

"

"

'

"

"

'

"

"

'

"

"

'

'

'

'

"

"

"

&

'

"

"

"

"

Example:
; B D

"

"

"

"

"

'

'

"

"

Cutting Speed:
" '  %   ! " , ! !  2  "    ( ! # !  . / ) ! " ,  !   !  "      ( !

'

"

'

"

CS
C    !   !  #    

"

"

"

"

"

"

"

'

"

"

"

"

'

"

"

"

'

'

"

"

"

&

"

"

"

"

'

"

&

"

&

"

"

'

"

"

'

"

Example: Example:
 " $    *   " 0 !  !

'

"

'

"

"

"

"

"

'

"

"

'

"

"

'

"

&

"

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'

"

'

"

'

"

'

"

'

"

" ( '  )  ! %

. B   

"

% '  " . 7    

"

"

pi
G C !  " ) $  " 2 ,   #  

'

"

"

"

'

"

'

&

'

'

"

'

"

'

"

"

"

'

"

'

'

'

 % ! " ,

"

Spindle Override:
  6 ' " # ( !  # " # $ # ) ! ,    # ) ! ,  $   (  # " !  #  $  ,   !  . " '     

&

"

'

"

"

"

'

'

'

"

'

"

"

&

"

"

&

"

"

'

"

"

"

'

"

"

Feed Rate Function (F-address).

# )  #  "    $  #   # *  # ) # ) ! (  # !     2      ,   ( $ #  $  " *  # ) $ ' #  , )  "      $      ! " "  ! , !   " $  # ) ! #  , ! $ % (   ) 

'

"

"

"

'

'

"

'

"

'

"

"

'

"

"

'

"

'

"

'

"

'

"

&

'

&

&

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"

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&

'

"

"

&

'

"

'

"

"

"

"

'

"

"

&

'

&

&

'

'

"

"

&

'

"

'

&

'

 " !  

&

'

'

"

"

"

&

'

"

"

"

"

"

"

&

'

&

# !   # !

'

&

"

'

'

"

Inverse Time Feed Rate. inverse time

F , ,     #  $  "  " # ) !  (   ' # ! "  ! 1 '   !  # $  $ ( ,  ! # !  $ ( (    % $   $ * !  0   (     ( ! # !  " C $   !  ! ! " , !  ( 

'

"

"

"

"

"

"

"

"

&

'

'

&

"

'

"

&

&

"

"

'

"

"

'

"

"

Feed Rate Override.

# ! ( , $       6 ' " # ( !  # " # *  # ) $ ' #  )     # ) ! ,  $ &   !   # # ) ! $ , !   #  $  , 

feed rate override

) ! ,  $   ( ( !   ' # #  (  # " !  % . $  # )  " , ' E  . " '       $ #    " *

"

'

"

"

'

'

"

&

"

"

"

'

"

"

'

"

"

Tool Function (T-address).

(  #   # $ $   )   ! G 7 /

'

'

"

'

"

'

"

'

'

"

"

"

"

"

"

"

"

"

"

"

'

"

'

'

"

"

"

"

'

"

'

"

"

"

"

'

'

"

"

"

"

'

"

"

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'

"

'

"

'

"

'

'

"

'

"

"

'

&

"

"

"

"

'

"

'

"

'

"

&

"

"

"

"

"

"

"

"

"

"

&

"

"

"

"

'

'

'

"

"

"

'

"

'

"

'

'

"

'

Tool Nose Radius Compensation.

 $ $      # ! , $   # "  !      !  #   %  $ (   ( !  "  $  " .

'

'

"

"

"

'

"

"

"

"

"

'

"

"

"

'

'

"

'

"

'

"

"

"

'

'

"

"

"

"

"

&

'

"

'

'

'

'

"

"

"

"

"

'

"

"

'

&

"

'

'

"

'

"

"

"

"

"

'

"

"

"

'

"

"

"

"

"

"

&

'

"

"

"

"

'

"

"

"

'

"

'

'

'

'

"

'

"

"

"

"

'

"

"

"

Rapid Motion (G00).

 $  5  ' # #   ( $ #  $  " G '  , $     $  5  ' # #       $  , '  , $ " !  " # $ ( $ & ! # ) !  '

"

"

"

&

'

"

'

&

'

"

'

&

"

'

&

&

"

"

"

"

"

"

'

'

"

'

'

"

'

&

'

Fig. 5
 !  # !  . 7 #   # 5 # ) ! $ # ) !   -

"

"

'

"

"

&

"

'

"

"

'

"

"

"

"

"

"

"

"

'

"

"

"

"

"

'

"

Linear Interpolation (G01).

*  # )   ' # #   % ! !    # !   ! % % !  # C 2 # $ # ) !  ! # G #   & !  "   # ) ! " ) $  ( $ #  $  ( $  ! G ,  $   ( ( !   

linear interpolation mode

) ! # $ $  ( $ & ! "   $      !   , " #   " #    ! C . / )  "  "  (  6 $ ( $  ! C 2 * ) !  ! # ) ! " ) $  # ! " #

'

"

"

"

"

'

"

"

"

&

interpolation
$     ,  $   ( (

"

"

"

"

"

"

"

"

"

"

"

'

"

"

&

"

'

"

"

"

"

'

"

Circular Interpolation (G02, G03). Circular interpolation

,  # ) ( $ &     $       $        ! . 7     G      ! C    0 ! ,  $    !    , ,  $  (  #  $  . / ) !  ' # #   ( $ #  $    $        " # * $ 5 #  + ! " ,    !    "    ! ,    ! . z $    $       ! !  " # "  "  # )  !

"

'

'

"

"

"

<

<

>

Figs. 6 8
[ _ ` a b c Q L J R E \ J V F d F M V F L E X I E I b c F G G V S M R J U E I J U J T M e E R f \ S E Q U K [ _ g a f b Q L J R E \ J V F d F M V F L E X I E I f b F G G V S M R J U E I J U J T M e E R c \ S E Q U K

a |

a |

K |

Fig. 9
U E V H M R E I U K E J V F e E F U G V I P G H E F G R U V G L I X I E

<

Helical and Other Interpolation Methods.

H G U M G R \ K E L M F J L M R U E V Q G L J U M G R ] E M U K E V J I J I U J R S Z E  I Q E F M J L M E S F G R U V G L I G Z Z E V Q J V J D G L M F G V K x Q E Q V G S X F E I J K E L M N P  G J N E I ] U x Q M F J L L x b c O Z G V H

Offsets for Milling

R

offset
J L M R ~ D E U  E E R U K E ~ R G  R M R Z G V H J U M G R J U U K E U M H E G Z Q V G T V J H H M R T J R S U K E R I M U X J U M G R J U U K E U M H E G Z I E U X Q J R S H J F K M R M R T P K E I M R T L E H G I U M H Q G V U J R U Q X V Q G I E I M I U G Q V G e M S E J S X I U H E R U I R E F E I I J V x U G ~ E E Q Q V E F M I E Q J V U S M H E R I M G R I P X F K J S X I U \

Work Offset Tool Length Offset Cutter Radius Offset Work Offset (G54 though G59).
a Z Z I E U U G L M R ~ a Z Z I E U U G L M R H J F K M R E V E Z E V E R F E Q G M R U ] J L I G ~ R G  R L G F J U M G R K J I F G G V S M R J U E I G Z b z c z f z E R F E D E U  E E R H J F K M R E E V G J R S Q J V U

work offset
E V G P L L H J F K M R E J N E I F J R D E I E U Y J L U K G X T K G R L x b J R S c J N E I J V E R G V H J L L x X I E S P

G |

<

Fig. 10
H J F K M R E E V G U G Q J V U E V G Y J L G R T J R J N M I P U x Q M F J L Q V G T V J H E R U V  M U K G U K E V S J U J Y Z G V E N J H Q L E ^ } [ h z [ [ z z b c z }

Tool Length Offset (G43, G44).

U J R F E D E U  E E R U K E U G G L V E Z E V E R F E Q G J e J M L J D L E \ U K E J R S U K E

tool length offset

M R U J R S Q J V U E V G Y J L G R T U K E f \ J N M I P  G H E U K G S I J V E P K E Q V E I E U H E U K G S V E W X M V E I J S S M \

preset method
U M G R J L E W X M Q H E R U J R S M I X I E S G Z Z \ H J F K S G R E J U U K E H J F K M R E P J F K U G G L X I G Z Z I E U P I Q E F M Z M F G Z Z I E U R X H D E V M I R E F E

touch-off method
M R E P K E U G X F K \ G Z Z H E U K G S M I H X F K I M H Q L E V Y J R S M I E S M R U K E Q V G T V J H R G V H J L L x V E W X M V E I G R E U G G L L E R T U K I I J V x U G M R F L X S E  M U K U K E [ } F G H H J R S P G V E N J H \

Fig. 11
I K G  I U x Q M F J L U G G L L E R T U K G Z Z I E U H E J I X V E H E R U X I M R T U K E U G X F K \ G Z Z H E U K G S  M U K [ } F G H \ H J R S P

Cutter Radius Offset (G41, G42).

U G X V U G G L Q J U K Z V G H U K E Q J V U E S T E U G U K E G V

cutter radius offset

F X U U E V F E R U E V P

cutter radius com] I E E Q J T E O P

pensation
y G M R U F J L F X L F J L U K J R Q V G T V I E U D x U K E F X U

tool nose radius compensation for lathes

J U M G R I D J I E S G R U K E S V J  M R T S M H E R I M G R I J V E Z J V H G J H H M R T F G G V S M R J U E I U G U K E F E R U E V G Z J F X U U E V P U E V V J S M X I P K E U G G L Q J U K T E R E V J U E S G R U K E D J I M I G Z S

1289
V E F G R e E R M E R U J R S Q V J F U M \ M L L X I U V J U E I J U G G L Q J U K G Z Z \

Fig. 12
V J  M R T S M H E R I M G R I H J x G R L x D E I X M U J D L E Z G V K G L E I  K E V E U K E I Q M R S L E F E R U E V L M R E J R S K G L E F E R U E V L M R E H J U F K P X F K J U G G L Q J U K F J R R G U D E X I E S G R J F G R U G X V D E F J X I E U K E F X U U E V F E R U E V L M R E H X I U D E I K M Z U E S \ G Z Z I E U \

equidistant toolpath
' . /  ( ) * + , ' . / 0 1 2 (

& 3 ) * + , . / 0 1 2

&

& . /

'

         

%  

#      

      

        

    

    !

 " 

<

Fig. 13
U E V U G G L Q J U K I F J R R G U D E J S X I U E S J U U K E H J F K M R E P G J F U M e J U E J F X U U E V V J S M X I G Z Z I E U Y U  G Q V E Q J V J U G V x F

Example:
[ _ _ J I U K E F X U U E V V J S M X I G Z Z I E U P [ z F G H H J R S F J R F E L y V G T V J H H M R T U K E F X U U E V V J S M X I G Z Z I E U M I V E L J U M e E L x I M H Q

Example:
X U U E V V J S T V J H E N E F X

Machining Holes
M
9

Table 4
I K G  I I x H D G L I J R S J D D V E e M J U M G R I X I E S M R U K E Z G L L G  M R T F x F L E S E I F V M Q U M G R I P

Table 4. Fixed Cycle Descriptions

:

<

>

: >

<

>

>

Fixed Cycles.
I E W X E R F E I G Z U G G L T L E D L G F ~ G Z Q V G T V

Table 5. Fixed Cycle Codes

v

>

<

>

<

>

<

>

>

Fig. 14

N__ G__ X__Y__ R__ Z__ P__ Q__ F__

a F a I U a Z M a J H a E a F X H J U I E E

Fixed Cycle (G81): Fig. 15

^ [ h h ] [ h g O [ g _ b c f R

>

>

r c d e

r c d d

u f m

Spot Drilling, Facing, Counterboring-sinking (G82) :

I Q G U S V M L L M R T Y I Q G U Z J F M R T Y F G X R U E V D G V M R T Y F G X R U E V I M R ~ M R T Y J R S J R x G U K E V G Q E V J U M G R  K E V E J S  E L L J U U K E D G U U G H G Z U K E K G L E M I V E W X M V E S P

Fig. 16
c f y L E Y  M U K U K E J S S E S Q J X I E y ] S  E L L O P y J X I E M I

r min
x U K E V E I X L U D x _ z z z P X H S  E L L  M L L D E z d ` z N _ z z z a g z H I P

Example: Deep Hole Drilling (G83):

X I M R T U K E Z G L L G  M R T Z G V H J U ^ [ h h

P |

Fig. 17
T E R E V J L V X L E G Z Q E F ~ S V M L L M R T M I U K J U U K E T V E J U E V U K E
J

Chip Breaking (G73):

Z G L L G  M R T Z G V H J U [ h h ] [ h g O [ ` } b c f
J

Fig. 18

Right Hand Thread (G84):

Fig. 19

Left Hand Thread (G74):

Fig. 20

Boring Cycle (G85):

Fig. 21

>

&

&

'

8 5 9 : 3 ; 4 < 6 = 5

Boring Cycle (G86):

Fig. 22

Boring Cycle (G76):

fine

Fig. 23

"

Back Boring (G87):

back boring

Fig. 24

Manual Boring (G88):

Fig. 25

Boring with Dwell (G89):

Fig. 26 Fixed Cycle Cancellation (G80) :

General Notes on Fixed Cycles:

Contouring.

Fig. 27

Turning and Boring.

Multiple

Repetitive Cycles

Table 6. Multiple Repetitive Cycles

                              !   !                   !  ! "

Roughing Cycle (G71):

P__ Q__ I__ K__ U__ W__ D__ F__ S__

U__ R__

P__ Q__ U__ W__ F__ S__

Repeated Finish Counting (G73):

Finish Cycle (G70):

P__ Q__ F__ S__

Basic Rules for G71, G73 Cycles:

Thread Cutting on CNC Lathes

single point threading

Depth of Thread Calculations.

TPI

TPI

Pitch

TPI Thread Pitch

Pitch

Pitch

TPI

Thread Lead

TPI

Infeed Methods.

Fig. 29

Radial Infeed.

Compound Infeed.

Threading Operations.

Threading Cycle (G32).

Threading Cycle (G76).

One Block Cycle:

X= Z= I= K= D= A=

P= F= Two Block Cycle:

P=
 

Q= R=

X= Z= R= P= Q= F=

Example:

Multi-start Threads.

Subprograms, Macros and Parametric Programming

Subprograms. Subprograms

1306

Fig. 30

Macros and Parametric Programming.

Basic Macro Skills.

Confirming Macro Capability.

Common Features and Applications.

Macro Structure.

Variables

Defined Variables Functions and Constants

Logical Functions

Macro Definition and Call.

Variable Definition (G65).

Fig. 31

2 $

) !  $ * + ,  , $  .

"   #

) ,  $ / .

  # 5 6 # 7 6 8

( 6 0

"   # $

%  & '

( # 

% 

Argument List 1

Table 7. Macro B Argument List

? @ A B C D E F @ N G N ? @ A B C D E F @ N G N ? @ A B C D E F @ N G N ? @ A B C D E F @ N G N F G H I J K L P M @ H D M L O G H I F J K L P M @ H D M L O G H I F J K L P M @ H D M L O G H I F J K L P M @ H D M L O L L Q O L L Q O L L Q O L L Q O

F I I H

U P V V

T W V X Y Z

F I I H

[ V \

] \ ^ _ `

b V Y

a c

h V _

g i G

F I I H

l V

k m

J \ n V o

F I I H

F I I H

q V

<

"

Types of Variables. Null Variable:

Local Variables:

Common Variables:

System Variables:

Variable Declarations and Expressions.

>

 >

Macro Functions.

Macro Arithmetic Functions:

 | | z  x v |

Example:


>

Trigonometric Functions:

Example:


Example:


Rounding Functions:

(1) ROUND:

>

(2) FIX:

(3) FUP:

Miscellaneous Functions:

(1) SQRT:

(2) ABS:

[ [

Logical Functions:

Example 1, (OR):

Example 2, (AND) :

Example 3, (XOR):

Branching and Looping.

IF function:

this condition is true

GOTOn Function:

WHILE function:

this condition is true

this condition is true

argument

Example :

Macro Example.

Fig. 32

O7051

N5 G65 P7051 X3.0 Y6.5 D4.5 H6 A5.0 S1

t          t      

O7051
r   s r r 

Axis Nomenclature

Fig. 1

Fig. 2

Fig. 3

X Y

Fig. 4 Z

X Z

Fig. 4

Fig. 5

X Y Z

A B C

U V W

"

Fig. 6

Fig. 6

Fig. 7

Fig. 8

X Y Z W A

Total Indicator Reading (TIR).

Fig. 9

Machine Tool Accuracy Accuracy, Repeatability, and Resolution:

Positioning Accuracy:

Positional Deviation xij

Mean Positional Deviation = 0.0003 = xj

Readings

Normal Curve

x-Axis

Target 10.0000

Mean (Avg.)
10.0003
    

Distance Between Increments = 0.001"



Fig. 1

normal distribution curve, X

positional deviation

mean posi

tional deviation.

standard deviation,

Fig. 2

64% of Readings 95.44% of Readings 99.74% of Readings +1 1

2

+2 +3
Mean (Avg.)

"

"

$ $

"

( Xij
i
' &

Xj )
%

Xij

Fig. 1

Xj

Fig. 1

Example: X xj

Fig. 3

x


x


j


x


x


Xj

"

"

n
( $ $ $ $ -

"

[(X
&

Xj )
% . . . 0 #

(X
% . / . . .

Xj )
%

(X
/ . . .

Xj )
% . / . . . #

(X
* 1

Xj )
%

(X

Xj ) ]
%

"

"

"

[(
#

)
% , %

( (
. /

)
% , %

(
" ( $ $

)
" 2

) ]
%

"

accuracy

<

P P P P
=  >  ?  8 D

<

Fig. 4

accuracy

xAxis TP1

TP2
W X

TP3
Y

TP4

TP5

Spread = Accuracy = 0.004

W Z Y

<

<

Table 1
r d h f s

Table 1. Degrees of Accuracy Expected with NC Machine Tools

Significance of Accuracy:
t f ` l k f a b b n k a i f a e h ` l k f b q a k i g s _ ^ _ b l e i k l p p f k g c a r f d

t z

Autocollimation:
_ b c a k a b i f k d g i d b g l m ` a b p d ` a i l k w x c d b c d g a e

t z

731

t M

Fig. 5
w a k j f i q l d f l n i f k

Y
u

Date Humidity Air Press. Air Temp. Mach. Temp.

+ 0.0010 + 0.0005

1984 / 6 / 11 Percent 41.00 In. Hg 27.36 Deg. F 77.50 Deg. F 76.50

Machining Center Axis Travel From 0.30 to 15.30

Axis - Y Runs - 8 Points - 16 In Increments of 1.0000

0.0005 15.30 0.0010 0.30 1.80

7 

3.30
8 <

4.80
8 7 8 B 8

6.30
9 7 8

7.80
K  7 8

9.30

10.80
8 8

12.30
B

13.80

Effect of Machine Accuracy on Part Tolerances

t z a k i i l p f k a e b f g a k f n g n a p p o g c l x e l e q k d e i g w n g n a p p o d e a b l e i k l p p l b E i l ^ O \ O i a e h a k h

Geometric Dimensioning and Tolerancing (GD&T)

t x g g l ` f q a k i i l p f k a e b f g o ` l p g i c a i k f p a i f i l ` a b c d e f t b n k a b o l m a q a k i d g a m m f b i f h o ` a b c d e f a e h b n i i d e j i l l p h

613 Table 2
s a b b n k a b o s v c f ` f e i w m d y i n k f a t

Table 2. Symbols and Feature Control Frames ANSI Y14.5M-1994 (R1999)

y axis

x axis

Center (axis) for Hole 2

45

Machinery's Handbook 29th Edition

0.005 A

Copyright 2012, Industrial Press Inc., New York, NY

0.005 A

Center (axis) for Hole 1

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True Position Tolerance Zone 2 (0.005 mm)

True Position Tolerance Zone

Hole 2

Table 2. Symbols and Feature Control Frames ANSI Y14.5M-1994 (R1999)

Machinery's Handbook 29th Edition

Tolerance band

Tolerance 0.005

Datum A

0.005 A

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

Table 2. Symbols and Feature Control Frames ANSI Y14.5M-1994 (R1999)

Machinery's Handbook 29th Edition

Tolerance 0.010

Datum A

0.010 A

Tolerance 0.010

0.005 A

Datum A

Copyright 2012, Industrial Press Inc., New York, NY

http://industrialpress.com

0.005 A

Table 2. Symbols and Feature Control Frames ANSI Y14.5M-1994 (R1999)

Machinery's Handbook 29th Edition

Runout at a Point (Axial)

Tolerance Zone

Copyright 2012, Industrial Press Inc., New York, NY

Runout at a Point (Radial)

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