Tool force calculation

Notifications Mark all as read. Unit inch metric. Note: Ultimate Strength shown for generic steel. Please enter the actual value of your workpiece material if available, for better accuracy You may look up this info through websites such as www. Face Mill Nomenclature d1 Effective cutting diameter: in mm. IPT chip load mm. E Machine efficiency factor: Direct Belt Drive.

Reduced feed per tooth: in. A calculator. CrossSectionalAreaOfChip in. F t Tangential cutting force: lb N. T Torque at the cutter: Nm in. P s at the cutter: HPc KW. This conversion tool converts force per unit area to any combination of force and area units and display a conversion scale for the value entered. This tool will calculate the torque generated around an axis by a force applied at right angle to a lever arm of a specified length. Chip thickness is the amount taken by each insert as it advances through the arc of the cut.

The metal removed by a single pass of one insert looks like a very thin crescent. Chip thickness is the thickness of the crescent anywhere along its arc, which makes its thickness vary from zero to a maximum usually equal to the fz.

Chip thickness increases until it equals the fz at the centerline of the cutter. Feed per tooth and chip thickness are equal only at the point where the crescent crosses the direction of feed, which is usually at the cutter centerline.

In other words, fz is a constant for a given operation, and the chip thickness is a variable that changes cyclically. Milling cutters can consume significant amounts of horsepower.

Very often it is the lack of horsepower that is the limiting factor when deciding on a particular operation. On applications where large-diameter cutters or heavy stock removal is necessary, it is advantageous to first calculate the necessary horsepower requirements. Workpiece material Hardness HB K factor.

Steels, plain-carbon alloy steels, 1. Precipitation-hardening stainless steels 1. Cast irons gray, ductile, malleable 2. Stainless steels, wrought irons, cast irons 1. Titanium 1. High-temp alloys, nickel- and cobalt-based Iron-based Nickel alloys Aluminum alloys kg 6. Magnesium alloys kg Copper 3. Copper alloys 3. Most peripheral milling cutters are made with helical teeth. Helical teeth enter the workpiece at a single point with impact progressively increasing across the width of the cut.

If the width of the workpiece is a whole multiple of the axial pitch of the cutter, a helical cutter can be designed to cut with practically uniform cutting force, explaining their wide preference.

Rate of change of position of the tool as a whole, relative to the workpiece while cutting. Hardness is a measure of the resistance of a material to surface indentation or abrasion. There is no absolute scale for hardness. In order to express hardness quantitatively, each type of test has its own scale, which defines hardness. Indentation hardness obtained through static methods is measured by Brinell, Rockwell, Vickers and Knoop tests.

Hardness without indentation is measured by a dynamic method, known as the Scleroscope test. Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes.

The engine lathe consists of a headstock and spindle, tailstock, bed, carriage complete with apron and cross slides. Features include gear- speed and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines.

Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces instruments, watches , normally without a power feed. See turning machine. Any machining process used to part metal or other material or give a workpiece a new configuration. Conventionally applies to machining operations in which a cutting tool mechanically removes material in the form of chips; applies to any process in which metal or material is removed to create new shapes.

See metalforming. Secures a cutting tool during a machining operation.