90 Indexable Positive Milling Cutter

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1 90 Indexable Positive Cutter Inserts HIGH POSITIVE 90 MILLING CUTTER Cutting Rake - 20 for 11 positive 85 parallelogram AP inserts Application TOOL ANGLES: Cutting Rake +20 Axial Rake 6 Radial Rake -6 FEATURES: Insert Type For insert information see pages E-42 to E-43. Available in 1/2", 5/8", 3/4", & 1.0" Weldon, R8, & arbor shank sizes Positive parallelogram Inserts, 11 clearance 3/8" cutting edge Smoother cutting Torx screw locking system Two cutting edges For spare part information see page E-177. End Mill Face Mill E-110

2 Selection Chart Inserts E-11

3 Starting Speeds and Feeds Inserts E-16

4 Starting Speed and Feed Examples Diameter of tool Inch Feed per revolution Inch/Rev Chip load Inch n Spindle speed Rev/Min rt Rows of teeth - Cutting speed Feet/Min Feed per minute Inch/Min z c Effective cutting teeth - z n Total teeth - Find the starting feed rate for a 1.5 inch diameter ( ) helical end mill with 9 total teeth (z n ) and 3 rows of inserts (rt). The material being machined is 4140 steel with a recommended starting speed of 375 surface feet per minute ( ) and a.008 ( ) inch per tooth chip load. Revolution Per x 12 n 375 x RPM 3.14 x 1.5 Inserts Number of Effective Teeth Revolution Zn 9 Zc 3 rt 3 x z c.008 x IPR.024 x IPM Diameter of toom Feed per revolution mm/rev Chip load mm n Spindle speed Rev/Min rt Rows of teeth - Cutting speed m/min Feed per minute mm/min z c Effect cutting teeth - z n Total teeth - Find the starting feed rate for a 40 mm diameter ( ) helical end mill with 9 total teeth (z n ) and 3 rows of inserts (rt). The material being machined is 4140 steel with a recommended starting speed of 114 surface meters per minute ( ) and a 0,2 ( ) inch per tooth chip load. Revolution Per x x 1000 n 907 RPM 3.14 x 40 Number of Effective Teeth Revolution Zc Zn rt x z c 0,2 x 3 0,6 mm/rev 0,6 x mm/min E-17

5 Formulas a e Radial depth of cut Inch a p Axial depth of cut Inch M Torque lb ft n Spindle speed Rev/Min Diameter of tool Inch Power requirements Hp Feed per revolution Inch/Rev Feed per tooth Inch/Tooth Q Metal removal rate Inch 3 /Min Cutting time Min Inserts k c Specific cutting force lbs/inch 2 Machined length Inch Cutting Speed Surface Feet per 12 Determine the cutting speed ( ) required for a 2-1/2" diameter cutter with a spindle speed of 600 RPM. Cutting speed Feet/Min Feed per minute Inch/Min z n Number of teeth in tool - x 2.5 x Feet/Min Revolution Per n x 12 Determine the spindle speed (n) required for turning a 2-1/2" diameter part with a cutting speed of 400 SFM. n 400 x Rev/Min x 2.5 Metal Removal Rate Inch 3 /Min Power Requirement Horsepower Q a e x a p x a x a x f x z x k p e z n c 396,000 Determine the metal removal rate (Q) required for cutting with a radial depth of 4.0, an axial depth of.300, a cutting speed of 400 SFM, and feed rate of 20 IPR. Q.300 x 4.0 x inch 3 /min Determine the power requirement ( ) for machining material with a cutting force of 181,750, a radial depth of 4.0, an axial depth of.300 with a spindle speed of 400 RPM, and feed rate per tooth of.008 and 6 total teeth. 4.0 x.300 x.008 x 400 x 6 x 181, HP 396,000 Cutting Time Determine the amount of time required to machine a 6" long part with a spindle speed of 600 RPM and feed rate of.015 IPR Min (40 Sec).015 x 600 E-18

6 Formulas a e Radial depth of cut mm a p Axial depth of cut mm Diameter of toom Feed per revolution mm/rev Feed per tooth mm/tooth k c Specific cutting force Nm Machined length mm Cutting Speed Surface Metres per 1000 Determine the cutting speed ( ) required for a 50mm diameter cutter with a spindle speed of 600 RPM. M Torque Nm n Spindle speed Rev/Min Power requirements kw Q Metal removal rate mm 3 /Min Cutting time Min Cutting speed m/min Feed per minute mm/min z c Effective cutting teeth - x 50 x ,25 m/min Inserts Revolution Per n x 1000 Determine the spindle speed (n) required for a 32mm diameter cutter with a cutting speed of 100 m/min. n 100 x 1000 x ,72 Rev/Min Metal Removal Rate mm 3 /Min Power Requirement Kilowatts Q a e x a p x a p x a e x x k c Determine the metal removal rate (Q) required for cutting with a radial depth of 100, an axial depth of 8,0, a cutting speed of 200 m/min and feed rate of 80 mm/min. Q 8,0 x 100 x mm 3 /min Determine the power requirement ( ) for machining material with a specific cutting force of , a radial depth of 100, an axial depth of 8,0, with a spindle speed of 200 RPM, and feed rate per tooth of 0,2 and 6 total teeth. 100 x 8,0 x 0,2 x 200 x kw Cutting Time Determine the amount of time required to machine a 200mm long part with a spindle speed of 600 RPM and feed rate of 0,4 mmpr ,4 x 600,83 Min (50 Sec) E-19

Machine Tools MILLING PROCESS. BY LAKSHMIPATHI YERRA Asst.professor Dept.of Mechanical Engg.

Machine Tools MILLING PROCESS. BY LAKSHMIPATHI YERRA Asst.professor Dept.of Mechanical Engg. Machine Tools MILLING PROCESS BY LAKSHMIPATHI YERRA Asst.professor Dept.of Mechanical Engg. FIG. 1 Typical parts and shapes produced by various cutting processes Fig. 2 Schematic illustration of milling