Milling Machine Formulas

Milling is the machining process that uses a rotary cutter to remove material by moving a cutter
across the workpiece. This can be done on one axis or several axes, the speed and pressure of the
cutter head are in a different direction.

We are going to look at some milling formulas for ease on the milling machine. Following are
the important milling formulas that are very useful while performing any milling operation in a
milling machine. Let's see this one by one.

Milling Formulas
Following are the important terms used in determining the milling formula:

1. Cutting speed
2. Effective or true cutting speed
3. Spindle speed
4. Feed
5. Maximum chip thickness
6. Metal removal rate
7. Specific cutting force
8. Depth of cut
9. Number of cutter teeth
10. Machining time
11. Net power and efficiency

Read Also: List of Important Terms Used in Lathe Machine Formula.

#1 Cutting Speed

The cutting speed of a milling cutter is its circumferential linear motion that results from
rotation. It is expressed in meters per minute. The cutting speed can be obtained from the
formula:

where,

 v = it is the speed of the cutter in m per min.

 d = cutter diameter in mm.
 n = Speed of the cutter in r.p.m.

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#2 Effective or True Cutting Speed

It indicates the surface speed over the effective diameter (DCap). This is necessary in order to
determine the correct cutting data at the actual depth of cut (ap).

It is used when you are working with round cutters, ball nose end mills, and cutters with large
corner radii, as well as the cutter's entry angle is less than 90 degrees.

#3 Spindle Speed

It is the number of revolutions per minute made by the milling tool on the spindle. This value is
determined by the recommended cutting speed value for an operation.

#4 Feed

The feed in a milling machine is defined as the rate with which the workpiece advances under
the cutter. The feed is expressed to the milling machine in the following three different ways:

#1 Feed per tooth (Sz)

It is the distance that the work advances in the time between joining by two successive teeth is
known as feed per tooth. It is usually represented in millimeters per tooth of the cutter.

#2 Feed per revolution (Srev)

It is the distance that the work advances in the time the cutter turns through one complete
revolution is known as feed per revolution. It is represented in millimeters per revolution of the
cutter.

#3 Feed per minute (Sm)

It is the distance by which the work moves in one minute is known as feed per minute. It is
usually represented in millimeters per minute.

The feed per tooth, the feed per cutter revolution, and the feed per minute are related by the
formula which is given below.

where,

 Z = number of teeth in the cutter.

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 n = Speed of the cutter in r.p.m.

#5 Maximum Chip Thickness

This is the result of cutter engagement as it refers to (fz). Chip thickness is a required value when
deciding whether to use the most productive table feed per tooth feed.

#1 Average chip thickness

It is also a useful value in determining the specific cutting force used for net power calculations.

#6 Metal Removal Rate

This is the volume of metal removed in cubic mm per minute (inch3/minute). It is designed using
values for cutting depth, width, and feed.

#7 Specific Cutting Force

A material constant is a factor used for strength calculations and is expressed in N/mm 2.

#8 Depth of Cut

It is defined as the thickness of the material removed in one pass of the work under the cutter.
The depth of cut is the perpendicular length that is measured between the original and final
surface of the workpiece and is represented in mm.

#9 Number of Cutter Teeth

The number of teeth on a milling cutter should be properly designed for effective machining
operation. Knowing the speed and feed to which the cutter will be subjected while in an
operation, the number of cutter teeth can be derived from the feed formula. The number of cutter
teeth is calculated from the equation:

The coarse teeth cutter having a lesser number of teeth on their periphery are efficient in metal
machining. The following are the advantages of a coarse teeth cutter.

1. Greater chip space may be provided.

2. Cutter tooth cross-section may be increased thereby increasing its strength.
3. The greater amount of rake angle can be provided on the cutter.

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4. Less power is required to drive the cutter.

5. Less sliding friction is produced between the tooth and the work. This reduces the
development of heat.
6. Longer life of the cutter may be obtained as the number of regrinds can be increased.

#10 Machining Time

The machining length (lm) is divided by the table feed (vf). The time required for any operation to
mill the surface can be calculated from the formula:

where,

 T = it is the time required to complete the cut in minutes.

 L = it is the length of the table travel to complete the cut in mm.
 Ss = it is the feed per totth in mm.
 Z = it is the number of teeth in the cutter.
 n = it is the the cutter r.p.m.

The figure shows the length of the table travel 'L' is composed of two parts: the length of the
work "C" and the approach length "A". The approach "A" is the distance through which the
cutter must be moved before the full depth of cut is reached.

#1 Approach length for plain milling cutter:

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Approach "A" for a plain milling cutter can be determined by the equation:

where,

 A = the approach in mm.

 B = the depth of cut in mm.
 C = the diameter of the cutter in mm.

#2 Approach length for face milling cutter:

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Referring to the above figure, the approach length for a face milling cutter can be calculated
from the equation:

where,

 A = it is the length of approach in mm.

 D = it is the cutter diameter.
 B = it is the width of the work.

Substituting the value of "C" in equation "A"

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#11 Net Power and Efficiency

This is a value, which assists in the calculation of net power to ensure that the machine can
withstand the operation of the cutter. The net power is expressed in (Pc) and efficiency is (η mt).

Average Cutting Speed and Feed of Different Materials

Let's Consider One Example

#1 Example

Evaluate the cutting parameters for the slab milling operation for the following date:

 Milling cutter diameter = 100 mm

 Cutter speed = 500 r.p.m
 Width of cutter = 100 mm
 Depth of cut = 5mm
 Table feed = 100 mm/min
 Length of workpiece = 50 cm
 Width of workpiece = 80 mm
 Number of teeth in cutter = 8

Ans: Cutter diameter = 100 mm, cutter speed = 500 r.pm.

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MRR = b.d.F

b = width of job = 80 mm, d = depth of cut = 5 mm, F = Table feed = 100 mm/min.

l = 500 mm, Here y = 4 mm

Conclusion
This is a complete list of milling formulas and definitions that are useful in any milling process
and milling cutter. Understanding how to calculate accurate cutting speed, feed per tooth, or
metal removal rate and machining time is very important for good results in any milling
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Read more articles on machines:

1. 8 Different Types of Drilling Machine [Explained with Pictures]

2. What are the types of mechanism used shape machine? [PDF]
3. 12 Different Types of CNC machine with PDF

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