Milling Machines and Cutters

What is a milling machine?

Milling is the machining process in which the removal of metal takes place due the cutting action of a
rotating milling cutter. In a milling machine, the cutter is rotating due to workpiece is fed against it. This
machine can hold more than one tool at a time. The cutter rotates at high speed, and because of the
many cutting edges, it removes metal at a very fast rate.

The machine can also hold one or a number of cutters at a time. Thus, the milling machine is one of the
most important machines int the workshop. In this machine, all the operations can perform with high
accuracy.

Th metal removal rate is high as compared to a lathe machine, planner machine, and shaper machine. It
has good accuracy and a better surface finished. This is why a milling machine finds wide application in
production work.

Parts of a Milling Machine?

Following are the different parts of a milling machine:

1. Base
2. Column
3. Saddle
4. Table
5. Overhanging arm
6. Front Brace
7. Spindle
8. Arbor
Base

 The base of the machine is grey iron casting and serves as a foundation member for all other
parts which rests on it.
 The base carries the column at its one end. In some other machines, the base is hollow and
works as a reservoir for cutting fluid.

Column

 The column is the main supporting frame mouted on the base.

 It is box-shaped and houses all the driving mechanism for the spindle and feed table.
 The front vertical face of the column is eqquiped with dovetail guideways for supporting the
knee.
 The top of the column is finished to hold an overarm that extends beyond the front of the
machine.

Knee

 The knee is a fixed grey iron casting that slides up and down on the vertical ways of the column
face.
 The adjustment of height is affected by an elevating screw mounted on the base that also
supports the knee.
 The knee houses the feed mechanism of the table and controls to operate it.
 The top face of the knee forms a slideway for the saddle that gives cross travel to the table.

Sadddle

 On the top of the knee is place the saddle, which slides on guideways set exactly at 90 degrees
to the column face.
 A crossfeed screw near the top of the knee engages a nut on the bottom of the saddle to move
it horizontally, by hand or power, to appply cross-feed.
 The top of the saddle is precisely machined to provide guideways for the table.

Table

 It rests on guideways on the saddle and travels longitudally.

 The top of the table is finished accurately and T-slots are provided for clamping the work and
other fixtures.
 A lead-screw id provided under the table that engages with a nut on the saddle, it helps to move
the table horizontally by hand or power.
 The longitudinal travel of the table possibly limited by fixing trip dogs on the side of the table.
 In universal machines, the table may also be swivelled horizontally. For this purpose, the table is
mounted on a circular base, which in its turn is mounted in the saddle.
 The circular base is graduated in degrees.
Overhanging arm

 Overhanging arm act as a support for the arbor.

 It is mounted on the top of the column extends outwards the column face and works as bearing
support for the other end of the arbor.
 The overhanging arm is adjustable so that the bearing support may be provided nearest to the
cuttter.
 More than one bearing support can be provided for the arbor.

Front brace

 It is extra support, which provides rigidly to the arbor an the knee.

 The front brace is fitted between the knee and overarm.
 The front brace is slotted to allow for the adjustment of the height of the knee relative to the
overarm.

Spindle

 The spindle of the machine is located in the upper part of the column and receives power from
the motor through belts, gears, and clutches and transmit it to the arbor.
 The front end of the spindle just projects from the column face and is provided with a tapered
hole into which various cutting tools and arbor may be inserted.
 The accuracy in metal machining by the cutter depends on the strength, accuracy, and rigidity
of the spindle.

Arbor

 Arbor is an extension of the machine spindle on which milling cutters are securely mounted and
rotated.
 These are made woth taper shanks for proper alignment with the machine spindles having taper
holes at their nose.
 The taper shank of the arbor match to Morse taper or self-release taper whose value id 7:24.
 The arbor maybe supported at the farthest end from the overhanging arm or maybe of
contilever type which is called stub arbor.

Working Principle of Milling Machine

The working principle of the milling machine, applied in the metal removing operation on a milling
machine. The work is rigidly clamped on the table of the machine and revolving multi teeth cutter
mounted either on the spindle.
The cutter revolves at a normal speed and the work fed slowly past the cutter. The work can be fed in a
lingitudinal, vertical or cross direction. As the work progress further, the cutter teeth remove the metal
from the work surface to produce the disired shape.

Size of Milling Machine

The size of the milling machine is determined by the dimensions of its maximum length of the
longitudinal, cross, and vertical travel of the table and also by the working surface of the machine. The
below image shows the typical size of a horizontal knee type milling machine.

In addition to the above dimensions, number of spindle speeds, number of feeds, power available,
spindle nose taper, net weight and the floor space required, etc. Should also be considered in order to
specify the machine fully.

Types of Milling Machines

Following are the different types of milling machines:

1. Column and knee type

1. Hand milling machine
2. Plain or horizontal milling machine
3. Vertical milling machine
4. Universal milling machine
5. Omniversal milling machine
2. Manufacturing type or fixed bed type
1. Simplex milling machine
2. Duplex milling machine
3. Triplex milling machine
3. Planer type milling machine
Column and Knee Type

For general shop work, the most used type of milling machine is the column and knee type
machine. where the table is mounted on the knee-casting which in turn is mounted on the vertical slides
of the main column.

The knee vertical adjustable on the column so that the table can be moved up and down to
accommodate work of various heights.

The column and knee type milling machines are classified.

 According to the various methods of supplying power to the table.

 Different movements of the table. and
 The different axis of rotation of the main spindle.

1. Hand Milling Machine

It simplest of all types of milling machine in which table feeding is controlled by hand. The cutter is
mounted on a horizontal arbor and is rotated by power.

This type of milling machine is of small in size and suitable for light and simple milling operations.
For Example, machining slots, grooves, and keyway.

2. Plain Milling Machine

These are much stronger than hand millers. The table feeding is done either by hand or power. the plain
milling machine having a horizontal spindle is also called as a horizontal spindle milling machine. The
table may be fed in a longitudinal, cross, or vertical directions.

The feed is:

Longitudinal – when the table is moved at right angles to the spindle.

Cross – when the table is moved parallel to the spindle.

Vertical – when the table is adjusted in the vertical plane.

3. Universal Milling Machine

It can be adapted to a wide range of milling operations. Here the table can be swiveled to any angle up
to 45-degrees on either side of the normal position.

In addition to 3 movements as mentioned earlier in a plain milling machine, the table may have the
fourth movement when it is fed at an angle to the milling cutter. Helical milling operation can also be
performed. The capacity of this type of machine is increased by using special attachments such as

Dividing head or index head.

Vertical milling attachment.

Rotary attachment.

Slotting attachment.

This machine can produce spur, bevel, spiral, twist drill, reamer, milling cutter. All operations that are
performed on a shaper can be done using a universal milling machine.

4. Ominversal Milling Machine

Here the table also has four movements of the universal milling machine. It can also be tilted in a
vertical plane by providing a swivel arrangement at the knee.

The additional swiveling arrangement of the table helps in machining spiral grooves in reamers and
bevel gears.
5. Vertical Milling Machine
Here the position of the spindle is vertical or perpendicular to the table. This type of machine is adapted
for machining grooves, slots, and flat surfaces.

The machine may be of the plain or universal type and has all the movements of the table for a proper
setting and feeding the work.

The spindle head is clamped to the vertical column which is swivelled at an angle. It allowing the milling
cutter fixed on the spindle to work on angular surfaces. In some machines, the spindle can also be
adjusted up or down relative to the work.

Manufacturing of Fixed Bed Type Milling Machine

These machines are large, heavy and rigid in construction. These machines differ from column and knee
type milling machines by the construction of its table mounting.

The table is mounted directly on the ways of a fixed bed. The table movement is restricted to
reciprocating at a right angle to the spindle axis with no provisions for cross or vertical adjustment.

It is classified as simplex, duplex, triplex based on a machine provided with the single, double and triple
spindle heads respectively.

 Simplex – single spindle head.

 Duplex – two-spindle head.
 Triplex – three spindle head.
Planer Type Milling Machine

This types of milling machine are also called as “Plano-Miller”. It is a massive machine used for heavy-
duty work having spindle heads adjustable in the vertical and transverse direction.

It relates to a planer and like a planning machine. This machine has a cross rail capable of being raised or
lowered carrying the cutters. It has their heads, and the saddles, all supported by rigid uprights.

This arrangement of driving multiple cutter spindles enables a number of work surfaces to be machined.
Thereby it obtains the great reduction in production time.

The essential difference between a planer and a Plano-miller lies in the table movement. In a planer, the
table moves to give the cutting speed. But in a Plano-milling machine, the table movement gives the
feed.

Types of Milling Cutters

A milling machine is a machine tool that cuts metal as the workpiece is fed against a rotating multipoint
cutter. The milling cutter rotates at a very high speed because of the multiple cutting edges, it cuts the
metal at a very fast rate. This machine can also hold single or multiple cutters at the same time.

Following are the different types of milling cutters:

1. Solid milling cutter

2. Tipped solid milling cutter
3. Inserted teeth milling cutter
4. Profile relieved milling cutter
5. Form relieved milling cutter
6. Arbor type milling cutter
7. Facing type milling cutter
8. Shank type milling cutter
9. Right-hand rotational cutter
10. Left-hand rotational cutter
11. Parallel or straight teeth cutter
12. Right-hand helical cutter
13. Left-hand helical cutter
14. Alternate helical teeth cutter
15. Standard milling cutter
 16. Special milling cutter

1. According To The Constructional Feature of The Cutter

Solid Cutter

A solid cutter has teeth with the cutter body. The cutters are of smaller diameter and made of one piece
material usually of (HSS) high-speed steel.

Tipped Solid Cutter

A tipped solid cutter is similar to a solid cutter, except that the cutter teeth are made of cemented
carbide or stellite tips which are brazed on the tool shanks of an ordinary tool steel cutter body to lower
the cost of the cutter.

Inserted Teeth Cutter

In large milling cutters, the teeth or blades are inserted or secured in a body of less expensive materials.
The blades are held in the cutter body by mechanical means. This arrangement reduces the cost of the
cutter and enables economy in maintenance, as a single tooth if broken can be readily replaced.

2. According To The Relief Characteristics of The Cutter Teeth

Profile Relieved Cutter

In this category of milling cutters, a relief to the cutting edges is provided by grinding a narrow land at
the back of the cutting edges. The profile relieved cutters generate flat, curved or irregular surfaces.

Form Relieved Cutter

Form relived cutter also known as surface milling. These cutters have curved relief provided at the
backside of the cutting edges. These cutters are sharpened by grinding the faces of the teeth. The form
relieved cutters are used for generating formed or contoured surfaces.

3. According To The Methods of Mounting The Cutter

Arbor Type Cutter

The arbor type cutters are provided with a central hole having a keyway for mounting them directly on
the milling machine arbor. Milling cutters having tapered or threaded holes are also available. They are
mounted on arbors of different designs.

Shank Type Cutter

The shank type cutters are provided with straight or tapered shank integral with cutter body. The
straight or tapered shanks are inserted into the spindle nose and are fixed to it by a draw bolt.

Facing Type Cutter

The facing type cutters are either bolted or attached directly to the spindle nose, or secured on the face
of a short arbor called stub arbor. The facing type cutters are mainly used to produce flat surfaces.

4. According To The direction of Rotation of The Cutter Teeth

Right Hand Cutter

A milling cutter is designated as a right-hand cutter which rotates in an anticlockwise direction when
viewed from the end of the spindle.
Left Hand Cutter

A milling cutter is designated as a left-hand cutter which rotates in a clockwise direction when viewed
from the end of the spindle.

5. According To The Direction of The Helix of The Cutter Teeth

Parallel or Straight Teeth Cutter

The parallel or straight teeth cutters have their straight or parallel to the axis of rotation of the cutter.
The helix angle of parallel teeth cutters is equal to zero.

Right Hand Helical Teeth Cutter

These cutters have their teeth cut at an angle to the axis of rotation of the cutter. The cutters may be
distinguished by viewing it from one of its end faces when the helical groove or flute will be found to
lead from left to right-hand direction of the cutter body.

Left Hand Helical Teeth Cutter

These cutters have their teeth cut at an angle to the axis of rotation of the cutter. The cutter may be
distinguished by viewing it from one of its end faces when the helical groove or flute will be found to
lead from right to left-hand direction of the cutter body.

Alternate Helical Teeth Cutter

In some cutters, the alternate teeth are provided with right and left and helical angles.

6. According To The Purpose or Use of The Cutter

Standard Helical Teeth Cutter

These cutters are a conventional type of milling cutters whose dimensions such as cutter diameter and
width, the diameter of the centre hole, width and depth of keyways, etc. are standardized.
Special Milling Cutter

Special milling cutters are designed to perform special operations which may be the combination of
several standard operations. The cutters may have standard or non-standard dimensions.

Machine Centers

1. Major Functions and Characteristics

Today, machining centers are widely used in manufacturing sites. Machining centers are critical
equipment for machining metal parts and components in addition to their primary purpose of die
manufacture. As an example, machining centers in the automobile industry are used for efficient
grinding and drilling of engine parts as well as for making dies for body components. Many other
products commonly used in daily life and in industrial settings are manufactured in machining centers.

Machining centers feature a computerized automatic tool change function. In general, an operator must
exchange the tools on an NC machine tool. Machining centers, however, have a change arm that
automatically retrieves and exchanges tools from a tool magazine where the tools are stored during the
machining of workpieces. This saves time and effort required for standard tool changeovers, and
consequentially enables automated and power-saving operations while reducing costs.

In recent years, the emergence of five-axis machining centers, equipped with two rotational axes in
addition to the conventional three axes, has enabled machining of shapes with even greater complexity.

Metalworking with machining center from CAD data

Product manufacturing based on die machining

2. Emergence and Development of Machining Centers

Manufacturing metal parts generally includes grinding surfaces and grooves in addition to using a
number of complex machining methods such as drilling, boring (enlarging holes), and threading.
Conventionally, different cutting tools such as mills, end mills, drills, boring tools, and taps were
selectively used for these machining processes.
With the emergence of NC lathes later on, a manually-operated tool change function called a turret was
developed, making blade exchanging more convenient. Machining centers take this idea one step
forward through computer-controlled automated tool exchanges. Machining centers can continuously
perform several types of machining at the same time on different surfaces of a workpiece, greatly
improving production efficiency. Even today machining centers are still improving with advances in
machining precision and speed year after year, making them a fundamental part of the manufacturing
process.

Visit any metalworking factory to see a number of machining centers working ceaselessly day in and day
out. Only a few on-site operators are required to monitor the machines.

With NC lathes, tools are attached to a

turret, which is turned manually.
 

A: Turret :

Machining centers are capable

of automatic tool exchanges.

3. General Structure and Types of Machining Centers

Machining centers can be broadly classified into three types based on their structure: horizontal, vertical, and
gantry types. The horizontal type—the first to be developed—can be defined simply as a machine where the
spindle to which the cutting tool is attached is mounted horizontally (or parallel to the floor). In contrast, vertical
types have the spindle set upright. Gantry types, on the other hand, have a gate-like structure with the spindle
mounted on the ceiling of the gate, facing downward.
Using the horizontal type as an example, the general structure of a machining center consists of a base part called
a bed at the bottom, a saddle that moves on the bed, a table attached on top of the saddle for placing the raw
material, a column installed perpendicularly to the bed, and a spindle head where the cutting tools are attached.

4. Differences Between Horizontal and Vertical Types

Horizontal machining centers have a blade-mounted spindle that comes out sideways, which machines
workpieces in the horizontal direction. The column moves along the X axis, the saddle along the Y axis,
and table along the Z axis, and this combination enables three-dimensional machining. Additionally,
some models have a B axis that rotates the table horizontally, making it possible to machine materials
using a total of four axes.
One advantage of horizontal types is the capability to machine four surfaces of a workpiece―when
using a four-axis machining center with B axis―all at once. This eliminates the need for operators to
manually switch the four sides of the workpiece, and thus also contributes to higher machining
precision. Moreover, machining from the horizontal direction allows chips to fall down, which helps
prevent the chips from accumulating on the workpiece and digging into the blade.

Conversely, vertical machining centers have the spindle in a vertical position, and workpieces are
machined from above. Generally, the table travels horizontally on the X and Y axes, and the spindle
moves vertically, enabling triaxial machining.
Compared with horizontal types where the spindle is situated to the side of the workpiece, vertical types
take up less installation space, making them a popular choice. In addition, machining from above the
workpiece allows operators to work while comparing the machining to the design drawings. However,
machining on the top of the workpiece causes chips to accumulate on the workpiece, creating the need
for a blower that uses compressed air, or rinsing with lubricant to remove the chips appropriately.

Vertical machining center

Cutting tool is vertical Horizontal machining center
Cutting tool is horizontal
A : Spindle with
tool attached
There is a total of 5 Indexing Head Methods:

1. Direct Indexing
2. Simple Indexing
3. Angular indexing
4. Compound Indexing and
5. Differential indexing
1. Direct Indexing Head:
The direct indexing is also called Rapid indexing, and it is used when a large number of pieces are
indexed with a small division.

This operation can be done in both plain and universal dividing head. When using the Universal head,
the worm and worm wheel are first disengaged.

The required number of divisions on the work is obtained by means of the rapid index plate which is
fitted at the front end of the spindle nose. The plate has 24 equally spaced holes.

The spring-loaded pin can be pushed into any of the holes to lock the spindle with the frame.
For indexing, the pin is taken out first and then spindle is rotated by hand, and after the required
position is reached it is again locked by the pin.
When the plate is turned through the required part of the revolution, the dividing head spindle and the
work are also turned through the same part of the revolution.

With a Rapid indexing plate of 20 holes, it is possible to divide the work into an equal division of
2,3,4,6,8,12 and 24 parts which are all the factors of 24.

To Find the index movement, find the total number of holes in the direct index plate by the number of
divisions required in the work, If N is the number of divisions required on the work then,

[Number of holes be removed= 24/N]

2. Simple Indexing Head:

Simple indexing is also called as 9 indexing. It is more accurate and has a large range of indexing than
rapid indexing.

For indexing, the dividing head spindle is turned by the index crank.
The worm shaft carrying the crank has a single-threaded worm which meshes with worm gear having 40
teeth, 40 turns of the crank are necessary to rotate the index head spindle through one revolution.

Therefore, one complete turn of the index crank will cause the worm wheel to make 1/40 of a
revolution. To facilitate indexing to the fraction of a turn, an Index plate is used to cover practically all
numbers.

The Index plate with a circle of holes manufactured by the brown and sharp company are:

 Plate No 1- 15,16,17,18,19,20
             2- 21,23,27,29,31,33
             3- 37,39,41,43,47,49
To find the index crank movement, divided 40 by  number of division required on the work,

[Index crank movement= 40/N]

Where N is the number of divisions required on the work.

3. Angular Indexing Head:

The angular indexing is the Process of dividing the periphery of work in angular measurements.

There are 360 degrees in a circle, and then the index crank is rotated by 40 number of revolution,

and the spindle rotates through 1 complete Revolution or by 360 degrees, one complete turn off the
crank will cause the spindle and the work to rotate through 360/40=9 degrees.

Therefore in order to turn work through a required angle, the number of turns required for index crank
can be calculated by the number ‘9’.

Angular displacement is expressed in minutes then the terms of the index crank can be calculated by
dividing the angle by 540.

If it is expressed in seconds then it is divided by 32400.

When a result is a whole number, the index crank is rotated through the full calculated number.

If the result is a fraction and a whole number,

the part of the revolution of the crank after turning the whole number is calculated by multiplying is
suitable for numbers to the numerator and denominator of the fraction, defecation to make the
denominator of the fraction is equal to the number of holes in the index plate circle and the now
numerator number for holes to be moved by the index Crank.
The index crank Movement= Angular displacement of work, in degrees / 9
                                       =  in minutes / 540
                                      =  in seconds / 32400

4. Compound Indexing Head:  

In Compound indexing, there are two separate movements of the index crank in two different hole
circles of one index plate to get the crank movement.

The index plate is held stationary by Lock pin heed which engages with one of the whole circle of the
index place from the back.

For indexing first, the crankpin is rotated by the required number of the spaces in one of the holes of the
circle of the index plate and then the pin is engaged with the plate.

The second index movement is done by removing the real lock pin and the rotating the plate together
with the index crank forward or backward through the calculated number of spaces of another hole
circle, and the lock pin is engaged.

The net movements are the sum of the movement, therefore,

[40/N = n1 /N1 + n2/N2]

Where  N is the number of divisions required

           N1 is the hole circle used by the crankpin
           N2 is hole circle used by the lock pin
           n1 is space moved by the crankpin in N1 hole circle
           n2 is the spaces moved by the plate and the crankpin in N 2 hole circle.

The basic knowledge about indexing, I think now you know.

So let’s look forward to solving the problem,

Q 1. Find out the index movement required to mill a hexagonal Bolt by direct indexing. The rapid
index plate has 24 holes.

Solution: Number of holes to be moved = 24/N

                                                               =24/6=4
Therefore after machining one side of the bolt, the index plate has to move by 4 holes for the next face
to the machine.

Q 2. Set the dividing head to mill 30 teeth on spur wheel blank by simple indexing.

Solution: Index Crank movement = 40/N

                                                 = 40/30
                                                 = 4/3
                                                 = 4/3 * 7/7 =1+(7/21)

1 Full turn and 7 holes in 21 holes circle of the index plate.

Cutting Speed and Feed

To operate any machine efficiently, the machinist must learn the importance of cutting speeds and
feeds. A lot of time can be lost if the machines are not set at the proper speed and feeds for the
workpiece.

In order to eliminate this time loss, we can, and should, use recommended metal-removal rates that
have been researched and tested by steel and cutting-tool manufactures. We can find these cutting
speeds and metal removal rates in our appendix or in the Machinery’s Handbook.

We can control the feed on an engine lathe by using the change gears in the quick-change gearbox. Our
textbook recommends whenever possible, only two cuts should be taken to bring a diameter to size: a
roughing cut and a finishing cut.

It has been my experience to take at least three cuts. One to remove excess material quickly: the rough
cut, one cut to establish finish and to allow for tool pressure, and one to finish the cut.

If you were cutting thread all day long: day in and day out. You might set the lathe up for only two cuts.
One cut to remove all but .002 or .003 of material and the last cut to hold size and finish. This is done all
the time in some shops today.

Have you noticed that when you take a very small cut on the lathe .001 to .002 that the finish is usually
poor, and that on the rough cut you made prior to this very light cut, the finish was good? The reason for
this is: some tool pressure is desirable when making finish cuts.

IPM = Inches Per Minute

RPM = Revolutions Per Minute

Feed = IPM

#T = Number of teeth in cutter

Feed/Tooth = Chip load per tooth allowed for material

Chip/Tooth = Feed per tooth allowed for material

Feed Rate = ChipTooth × #T × RPM

Example: Material = Aluminum 3” Cutter, 5 Teeth Chip Load = 0.018 per tooth RPM = 3000 IPS = 0.018 ×
5 × 3000 = 270 Inches Per Minute

SPEED, FEED, AND DEPTH OF CUT

1. Cutting speed is defined as the speed (usually in feet per minute) of a tool when it is cutting the work.

2. Feed rate is defined as tool’s distance travelled during one spindle revolution.

3. Feed rate and cutting speed determine the rate of material removal, power requirements, and surface
finish.

4. Feed rate and cutting speed are mostly determined by the material that’s being cut. In addition, the
deepness of the cut, size and condition of the lathe, and rigidity of the lathe should still be considered.

5. Roughing cuts (0.01 in. to 0.03 in. depth of cut) for most aluminum alloys run at a feedrate of .005
inches per minute (IPM) to 0.02 IPM while finishing cuts (0.002 in. to 0.012 in. depth of cut) run at 0.002
IPM to 0.004 IPM.

6. As the softness of the material decreases, the cutting speed increases. Additionally, as the cutting tool
material becomes stronger, the cutting speed increases.

7. Remember, for each thousandth depth of cut, the diameter of the stock is reduced by two
thousandths.

Steel            Iron         Aluminum             Lead

Figure 1: Increasing Cutting Speed Based on work material hardness

Carbon Steel             High Speed Steel            Carbide

Figure 2: Increasing Cutting Speed Based on Cutting tool hardness

Cutting Speeds:

A lathe work cutting speed may be defined as the rate at which a point on the work circumference
travels past the cutting tool. Cutting speed is always expressed in meters per minute (m/min) or in feet
per minute (ft/min.) industry demands that machining operations be performed as quickly as possible;
therefore current cutting speeds must be used for the type of material being cut. If a cutting speed is too
high, the cutting tool edge breaks down rapidly, resulting in time lost recondition the tool. With too slow
a cutting speed, time will be lost for the machining operation, resulting in low production rates. Based
on research and testing by steel and cutting tool manufacturers, see lathe cutting speed table below.
The cutting speeds for high speed steel listed below are recommended for efficient metal removal rates.
These speeds may be varied slightly to shift factors such as the condition of the machine, the type of
work material and sand or hard spots in the metal. The RPM at which the lathe should be set for cutting
metals is as follows:

To determine the RPM of the lathe while performing procedures on it:

Formula: RPM = (CuttingSpeed x 4) / Diameter

We first must find what the recommended cutting speed is for the material we are going to machine.

Learn to use the Machinery’s Handbook and other related sources to obtain the information you need.

EXAMPLE: How fast should a 3/8 inch drill be turning when drilling mild steel?

From our recommended cutting speed from our class handouts, use a cutting speed of 100 for mild
steel.

(100 x 4) / .375 = 1066 RPM

What would the RPM be if we were turning a .375 diameter workpiece made out of mild steel on the
lathe?

RPM = 100 X4 / 1.00 = 400 RPM

Recommended Cutting Speeds for Six Materials in RPM

These charts are for HSS tools. If using carbide, the rates may be increased.

Lathe Feed:

The feed of a lathe is the distance the cutting tool advances along the length of the work for every
revolution of the spindle. For example, if the lathe is set for a .020 inch feed, the cutting tool will travel
the length of the work .020 inch for every complete turn that work makes. The feed of a lathe is
dependent upon the speed of the lead screw or feed rod. The speed is controlled by the change gears in
the quick change gearbox.

Whenever possible, only two cut should be taken to bring a diameter cut. Since the purpose of a rough
cut is to remove excess material quickly and surface finish is not too important. A coarse feed should be
used. The finishing cut is used to bring the diameter to size and produce a good surface finish and
therefore a fine feed should be used.

The recommended feeds for cutting various materials when using a high speed steel cutting tools listed
in table below. For general purpose machining a .005 – .020 inch feed for roughing and a .012 to .004
inch feed for finishing is recommended.

To select the proper feed rate for drilling, you must consider several factors.

1. Depth of hole – chip removal

2. Material type – machinability

3. Coolant – flood, mist, brush

4. Size of drill

5. How strong is the setup?

6. Hole finish and accuracy

Feed Rates for Turning:

For general purpose machining, use a recommended feed rate of .005 – .020 inches per revolution for
roughing and a .002 – .004 inches per revolution for finishing.

Feeds for Various Materials (using HSS cutting tool)

Setting speeds on a lathe:

The lathes are designed to operate at various spindle speeds for machining of different materials. There
speeds are measured in RPM (revolutions per minute) and are changed by the cone pulleys or gear
levels. One a belt-driven lathe, various speeds are obtained by changing the flat belt and the back gear
drive. One the geared-head lathe speeds are changed by moving the speed levers into proper positions
according to the RPM chart fastened to the lathe machine (mostly on headstock). While shifting the
lever positions, place one hand on the faceplate or chuck, and form the face plate slowly by hand. This
will enable the levers for engage the gear teeth without clashing. Never change speeds when the lathe is
running on lathers equipped with variable speed drivers, the speed is changed by turning a dial of
handle while he machine is running.

Setting feeds:

The feed of on lathe, or the distance the carriage will travel in on revolution of the spindle, depends on
the speed of the feed rod or lead screw. This is controlled by the change gears in the quick-change
gearbox. This quick change gearbox obtains its drive from the head stock spindle through the end gear
train. A feeds and thread chart mounted on the front of the quick-change gearbox indicates the various
feeds and metric pitches or thread per inch which may be obtained by setting levers to the positions
indicated.

To set the feedrate for Acura Lathe:

Example:

1. Select the desired feedrate on the chart (See Figure 2)

2. Select federate of .007 – LCS8W (See Figure 2)

3. L = Select High/Low lever (See Figure 3)

4. C = Select Feed Ranges and change to C on this lever (See Figure 3)

5. S = Select Feed Ranges and change to S on this lever (See Figure 3)

6. 8 = Select Gear Box and change to 8 on this lever (See Figure 3)

7.W = Select Feed Ranges and change to W on this lever (See Figure 3) Before turning on the lathe, be
sure all levers are fully engaged by turning the headstock spindle by hand, and see that the feed rod
turns.