Milling

Ref.N
Part No Part Description Raw material RM Size
o

1 76009914-001 Cover, Tranformer Al Alloy 6061-T6 100 x 100 x 6.35

Heatsink, TADS/PNVS power supply

2 76009924 Al Alloy 6061-T651 175 X 160 X 38
(TPPS)

Cover, tactical, programmable power

3 76009928-001 Al Alloy 6061-T651 165 x 146 x 31.75
supply (TPPS)

Page 1
 Milling
Cover, tactical, programmable power
3 76009928-001 Al Alloy 6061-T651 165 x 146 x 31.75
supply (TPPS)

4 76009953 Plate, Access, PSI Al Alloy 6061-T6 100 x 90 x 6.35

5 76009952-001 Cover, RPS Al Alloy 6061-T651 220 x 160 x 50.8

7 76009954 Bracket Assy, Connector Mounting

Page 2 Al Alloy 6061-T651 95 x 31.75 x 6.35
 Milling

7 76009954 Bracket Assy, Connector Mounting Al Alloy 6061-T651 95 x 31.75 x 6.35

11.1.1 - Top panel Al Alloy 6061-T651 280 x 230 x 31.75

290 x 31.75 x
11.2 - Front Panel Al Alloy 6061-T651
19.05

11.3.1
& - Left Panel & Right Panel Al Alloy 6061-T651 280 x 190 x 30
11.4.1

11.5.1 - AFT Panel Al Alloy 6061-T651 300 x 190 x 44.5

Page 3
 Milling
11.5.1 - AFT Panel Al Alloy 6061-T651 300 x 190 x 44.5

15-5PH
12 76009906 Bracket, Mounting CSUE 55 x 38.1 x 22.225
CONDITION 'A'

13 76009951 Cover Front PSI Al Alloy 6061-T651 240 x 177.8 x 12.7

14 76009948 Bracket, Cable Mount Al Alloy 6061-T651 105 x 72 x 5.08

Page 4
14 76009948 Bracket, Cable Mount Al Alloy 6061-T651 105 x 72 x 5.08
Milling

15 76009944 Cover, Access, Rear, VPC Al Alloy 6061-T651 95 x 25.4 x 6.35

16 76009918 Cover, Access, Rear, VPC Al Alloy 6061-T651 235 x 190 x 3

Chassis, Brazement, Power AID

21 76009943 Al Alloy 6061-T651 260 x 190 x 63.5
system interface (PSI)

Page 5
 Milling

Length of
Type of Operation Cutter Diameter (mm) No of cutting teeth
component

Milling 12 3 100

Milling 10 3 78.74

Milling 3 3 370.8

Milling

Milling 16 3 175

Milling 12 3 139

Milling 5 3 592

Milling 8 3 157.988

Milling 3 3 8.255

Milling 5 3 300

Milling 5 3 170.18

Milling 6 3 623.4176

Milling 5 3 97.7392

Milling 5 3 22.86

Milling

Milling 16 3 165

Milling 16 3 131

Milling 16 3 138

Milling 3 3 520

Page 6
 Milling

Milling 1.5 3 130

Milling 8 3 591

Milling

Milling 12 3 100

Milling 6 3 329.946

Milling

Milling 20 3 220

Milling 8 3 707.39

Milling 12 3 160.5788

Milling 12 3 555.498

Milling 16 3 206.375

Milling 16 3 184.15

Milling 4 3 84.582

Milling

Milling

Milling

Milling

Milling

Milling

Milling

Milling 8 3 85.217

Page 7
 Milling

Milling 3 3 43.18

Milling 20 3 280

Milling 16 3 193.04

Milling 3.175 3 193.04

Milling 16 3 215.9

Milling 10 3 1020

Milling 4 3 15.494

Milling 12 3 275

Milling 4 3 50

Milling

Milling 20 3 280

Milling 6 3 46.99

Milling 6 3 34.1376

Milling 20 3 212.09

Milling

Milling

Milling

Milling 20 3 300

Milling 16 3 259.08

Milling 16 3 111.506

Milling 16 3 268.8336

Page 8
 Milling

Milling 6 3 180.594

Milling 6 3 119.38

Milling 6 3 91.4908

Milling 12 3 33.655

Milling 3 3 33.655

Milling 4 3 33.655

Milling 12 3 33.2232

Milling 6 3 59.8551

Milling

Milling

Milling 16 3 240

Milling 12 3 206.883

Milling 12 3 739.648

Milling 12 3 85.79231

Milling 12 3 81.003902

Milling 12 3 95.76816

Milling 12 3 123.301506

Milling 12 3 133.277356

Milling

Milling 8 3 74.168

Milling 5 3 33.119822

Milling 6 3 400

Page 9
 Milling

Milling 10 3 95

Milling 5 3 11.176

Milling 2.5 3 33.655

Milling 6 3 801.116

Milling 20 3 260

Milling 20 3 838.2

Milling 8 3 838.2

Milling 10 3 215

Milling 6 3 22

Milling 10 3 213

Milling

Page 10
 Milling

Machining parameters

Table feed
Depth of cut
mm/min
Cutting Speed Feed mm/min (Chart
Spindle Speed (rpm)
m/min (Chart Value) Value)

25.00 0.20 663.06 397.84 1.50

20.00 0.18 636.54 343.73 0.50

15.00 0.15 1591.34 716.10 1.00

100.00 0.05 #DIV/0! #DIV/0! 0.20

35.00 0.35 696.21 731.02 1.50

35.00 0.25 928.28 696.21 1.00

20.00 0.15 1273.07 572.88 1.00

35.00 0.25 1392.43 1044.32 1.00

18.00 0.08 1909.61 458.31 0.30

20.00 0.08 1273.07 305.54 0.20

20.00 0.08 1273.07 305.54 0.20

35.00 0.10 1856.57 556.97 0.20

18.00 0.10 1145.77 343.73 0.20

20.00 0.08 1273.07 305.54 0.20

20.00 0.08 #DIV/0! #DIV/0! 0.20

40.00 0.35 795.67 835.46 1.50

35.00 0.30 696.21 626.59 0.50

35.00 0.30 696.21 626.59 1.00

20.00 0.12 2121.79 763.84 1.00

Page 11
 Milling

20.00 0.05 4243.58 636.54 1.00

40.00 0.25 1591.34 1193.51 1.00

20.00 0.12 #DIV/0! #DIV/0! 1.00

25.00 0.20 663.06 397.84 1.50

25.00 0.20 1326.12 795.67 0.50

100.00 0.05 #DIV/0! #DIV/0! 0.20

45.00 0.40 716.10 859.33 1.50

40.00 0.15 1591.34 716.10 0.50

40.00 0.30 1060.90 954.81 1.00

40.00 0.30 1060.90 954.81 1.00

40.00 0.35 795.67 835.46 0.30

40.00 0.35 795.67 835.46 0.20

25.00 0.18 1989.18 1074.16 0.20

25.00 0.35 #DIV/0! #DIV/0! 1.50

30.00 0.20 #DIV/0! #DIV/0! 0.50

10.00 0.05 #DIV/0! #DIV/0! 1.00

40.00 0.25 #DIV/0! #DIV/0! 1.00

25.00 0.10 #DIV/0! #DIV/0! 0.30

20.00 0.08 #DIV/0! #DIV/0! 0.20

100.00 0.05 #DIV/0! #DIV/0! 0.20

25.00 0.25 994.59 745.94 1.50

Page 12
 Milling

18.00 0.04 1909.61 229.15 0.50

60.00 0.40 954.81 1145.77 1.50

35.00 0.30 696.21 626.59 0.50

16.00 0.10 1603.87 481.16 1.00

35.00 0.30 696.21 626.59 1.00

50.00 0.35 1591.34 1670.91 0.30

18.00 0.08 1432.21 343.73 0.20

40.00 0.30 1060.90 954.81 1.50

20.00 0.20 1591.34 954.81 0.50

10.00 0.05 #DIV/0! #DIV/0! 1.00

60.00 0.40 954.81 1145.77 1.50

30.00 0.20 1591.34 954.81 0.50

30.00 0.20 1591.34 954.81 1.00

45.00 0.30 716.10 644.49 1.00

25.00 0.10 #DIV/0! #DIV/0! 0.30

20.00 0.08 #DIV/0! #DIV/0! 0.20

100.00 0.05 #DIV/0! #DIV/0! 0.20

60.00 0.40 954.81 1145.77 1.50

45.00 0.35 895.13 939.89 0.50

45.00 0.35 895.13 939.89 1.00

50.00 0.35 994.59 1044.32 1.00

Page 13
 Milling

30.00 0.25 1591.34 1193.51 0.30

30.00 0.25 1591.34 1193.51 0.20

100.00 0.05 5304.48 795.67 0.20

20.00 0.20 530.45 318.27 1.50

18.00 0.08 1909.61 458.31 0.50

10.00 0.08 795.67 190.96 1.00

40.00 0.25 1060.90 795.67 1.00

20.00 0.10 1060.90 318.27 0.30

20.00 0.08 #DIV/0! #DIV/0! 0.20

100.00 0.05 #DIV/0! #DIV/0! 0.20

50.00 0.45 994.59 1342.70 1.50

40.00 0.35 1060.90 1113.94 0.50

35.00 0.30 928.28 835.46 1.00

35.00 0.30 928.28 835.46 1.00

35.00 0.30 928.28 835.46 0.30

35.00 0.30 928.28 835.46 0.20

35.00 0.30 928.28 835.46 0.20

35.00 0.30 928.28 835.46 0.20

100.00 0.05 #DIV/0! #DIV/0! 0.20

20.00 0.20 795.67 477.40 1.50

30.00 0.25 288.29 216.22 0.50

30.00 0.25 1591.34 1193.51 1.50

Page 14
 Milling

40.00 0.35 1273.07 1336.73 1.50

20.00 0.10 1273.07 381.92 0.50

15.00 0.05 1909.61 286.44 1.00

30.00 0.25 1591.34 1193.51 1.50

45.00 0.40 716.10 859.33 1.50

45.00 0.30 716.10 644.49 0.50

40.00 0.30 1591.34 1432.21 1.00

45.00 0.20 1432.21 859.33 1.00

25.00 0.10 1326.12 397.84 0.30

30.00 0.30 954.81 859.33 0.20

100.00 0.05 #DIV/0! #DIV/0! 0.20

Page 15
 Milling

Approached Length (mm)

Metal Removal Rate Cycle time for No of passes

(mm^3/min) each pass (min) Required
t ( D-t) Sq.root (t (D-t) )

7161 15.75 3.97 0.26 15.00

1719 4.75 2.18 0.24 30.00

2148 2.00 1.41 0.52 4.00

#DIV/0! -0.04 Err:502 Err:502

17545 21.75 4.66 0.25 51.00

8355 11.00 3.32 0.21 143.00

2864 4.00 2.00 1.04 40.00

8355 7.00 2.65 0.15 52.00

412 0.81 0.90 0.02 560.00

306 0.96 0.98 0.99 5.00

306 0.96 0.98 0.56 5.00

668 1.16 1.08 1.12 13.00

344 0.96 0.98 0.29 24.00

306 0.96 0.98 0.08 15.00

#DIV/0! -0.04 Err:502 Err:502

20051 21.75 4.66 0.20 100.00

5013 7.75 2.78 0.21 33.00

10025 15.00 3.87 0.23 162.00

2292 2.00 1.41 0.68 60.00

Page 16
 Milling

955 0.50 0.71 0.21 119.00

9548 7.00 2.65 0.50 30.00

#DIV/0! -1.00 Err:502 Err:502

7161 15.75 3.97 0.26 27.00

2387 2.75 1.66 0.42 10.00

#DIV/0! -0.04 Err:502 Err:502

25780 27.75 5.27 0.26 90.00

2864 3.75 1.94 0.99 18.00

11458 11.00 3.32 0.17 150.00

11458 11.00 3.32 0.59 60.00

4010 4.71 2.17 0.25 24.00

2673 3.16 1.78 0.22 36.00

859 0.76 0.87 0.08 195.00

#DIV/0! -2.25 Err:502 Err:502

#DIV/0! -0.25 Err:502 Err:502

#DIV/0! -1.00 Err:502 Err:502

#DIV/0! -1.00 Err:502 Err:502

#DIV/0! -0.09 Err:502 Err:502

#DIV/0! -0.04 Err:502 Err:502

#DIV/0! -0.04 Err:502 Err:502

8951 9.75 3.12 0.12 32.00

Page 17
 Milling

344 1.25 1.12 0.19 9.00

34373 27.75 5.27 0.25 104.00

5013 7.75 2.78 0.31 126.00

1528 2.18 1.47 0.40 48.00

10025 15.00 3.87 0.35 70.00

5013 2.91 1.71 0.61 40.00

275 0.76 0.87 0.05 208.00

17187 15.75 3.97 0.29 32.00

1910 1.75 1.32 0.05 150.00

#DIV/0! -1.00 Err:502 Err:502

34373 27.75 5.27 0.25 100.00

2864 2.75 1.66 0.05 1280.00

5729 5.00 2.24 0.04 160.00

12890 19.00 4.36 0.34 64.00

#DIV/0! -0.09 Err:502 Err:502

#DIV/0! -0.04 Err:502 Err:502

#DIV/0! -0.04 Err:502 Err:502

34373 27.75 5.27 0.27 100.00

7519 7.75 2.78 0.28 120.00

15038 15.00 3.87 0.12 110.00

16709 15.00 3.87 0.26 168.00

Page 18
 Milling

2148 1.71 1.31 0.15 240.00

1432 1.16 1.08 0.10 120.00

955 1.16 1.08 0.12 120.00

5729 15.75 3.97 0.12 20.00

687 1.25 1.12 0.08 24.00

764 3.00 1.73 0.19 24.00

9548 11.00 3.32 0.05 160.00

573 1.71 1.31 0.19 9.00

#DIV/0! -0.04 Err:502 Err:502

#DIV/0! -0.04 Err:502 Err:502

32225 21.75 4.66 0.18 120.00

6684 5.75 2.40 0.19 104.00

10025 11.00 3.32 0.89 12.00

10025 11.00 3.32 0.11 16.00

3008 3.51 1.87 0.10 32.00

2005 2.36 1.54 0.12 16.00

2005 2.36 1.54 0.15 20.00

2005 2.36 1.54 0.16 16.00

#DIV/0! -0.04 Err:502 Err:502 16.00

5729 9.75 3.12 0.16 54.00

3581 16.31 4.04 0.17 24.00

10742 6.75 2.60 0.34 35.00

Page 19
 Milling

20051 12.75 3.57 0.07 80.00

955 2.25 1.50 0.03 24.00

716 1.50 1.22 0.12 16.00

10742 6.75 2.60 0.67 30.00

25780 27.75 5.27 0.31 100.00

6445 9.75 3.12 1.31 40.00

11458 7.00 2.65 0.59 12.00

8593 9.00 3.00 0.25 300.00

716 1.71 1.31 0.06 140.00

1719 1.96 1.40 0.25 60.00

#DIV/0! -0.04 Err:502 Err:502

Page 20
 Milling

For Drilling
Total Cycle Time
Cycle time (min) Remarks
(min)
Hole dia

3.92 16 3.4544

7.06 5.588

2.08 13.06

12.53 138 2.2606

29.33 173 5.461

41.51 2.5

8.00 2.8448

11.19

4.93
132.92
2.80

14.58

6.89

1.17

20.31 149 3.5814

7.03 164 3.4544

36.64 5.588

40.96
144.38

Page 21
 Milling
144.38
24.51

14.93

7.06 14 3.5814

4.17 5.969
11.22

23.59 138 2.413

17.83 165 3.5814

25.75 3.8608

35.12 7.3406
131.80
5.99

8.01

15.51

Err:502 Err:502

Err:502 Err:502

Err:502

Err:502
Err:502
Err:502

Err:502

Err:502

3.79 6 6.35

5.53 Page 22
 Milling

1.74 5.53 6

25.89 152 7.1374

39.38 183 3.2639

19.40 4.0386

24.55 143.59

24.46

9.90

9.35 19 6.5278

8.06 20 3.2639
17.41
4.2926

24.90 118

65.22 165

6.10

21.49
117.70

26.64 198 7.1374

33.43 238 7.1374

13.50 4.0386

43.87 14.2748
180.10
Page 23
 Milling
180.10
36.58 3.2639

12.11

13.96

2.36 20 4.9276

1.82 22 8.89

4.45 6.604

7.35 11.9126
17.71
1.73

21.87 72 3.9624

19.54 80 3.5814

10.67 3.4544

1.71 5.969

3.17
64.39
1.86

2.99

2.58

8.74 25

4.12 28
24.67
11.81

Page 24
 24.67
Milling

5.90 9

0.80 11
8.64
1.95

20.20 20
20.20

30.87 189

52.22 256

7.05

76.15
189.44
8.18

14.97

Page 25
 Milling

For Drilling

length of hole Cutting speed feed spindle speed

4.6 12 0.04 1105.61

1.8 12 0.04 683.47

10 0.03 #DIV/0!

10 0.03 #DIV/0!

6.1722 10 0.02 1407.89

1.778 15 0.025 874.20

8 10 0.03 1118.77

6.096 15 0.015 1678.16

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

21.59 15 0.035 1333.01

21 15 0.035 1382.01

1.6 15 0.03 854.34

10 0.03 #DIV/0!

Page 26
 Milling

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

5 12 0.03 1066.41

1.6 12 0.03 639.84

10 0.03 #DIV/0!

50 18 0.01 2374.15

4 15 0.025 1333.01

3 12 0.02 989.23

1.6 10 0.04 433.57

7 0.02 #DIV/0!

7 0.025 #DIV/0!

15 0.04 #DIV/0!

8 0.025 #DIV/0!

10 0.03 #DIV/0!

10 0.03 #DIV/0!

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

3.81 12 0.04 601.45

Page 27
 Milling

8 0.025 #DIV/0!

8 12 0.06 535.10

25 15 0.03 1462.68

25 15 0.04 1182.10

10 0.03 #DIV/0!

7 0.02 #DIV/0!

7 0.025 #DIV/0!

3.048 12 0.04 585.07

3.048 12 0.015 1170.14

1.6 10 0.015 741.44

15 0.04 #DIV/0!

8 0.025 #DIV/0!

10 0.03 #DIV/0!

10 0.03 #DIV/0!

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

4.064 10 0.04 445.92

5.08 10 0.04 445.92

5 12 0.025 945.68

1.5748 10 0.05 222.96

Page 28
 Milling

26.162 7 0.02 682.58

7 0.025 #DIV/0!

10 0.03 #DIV/0!

4.318 15 0.015 968.83

2.413 10 0.03 358.01

9.525 10 0.03 481.93

7.5438 10 0.03 267.17

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

1.524 15 0.018 1204.83

1.524 15 0.018 1333.01

2.54 15 0.018 1382.01

1.5 15 0.025 799.80

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

15 0.04 #DIV/0!

8 0.025 #DIV/0!

Page 29
 Milling

15 0.04 #DIV/0!

8 0.025 #DIV/0!

10 0.03 #DIV/0!

15 0.04 #DIV/0!

15 0.04 #DIV/0!

8 0.025 #DIV/0!

10 0.03 #DIV/0!

10 0.03 #DIV/0!

7 0.02 #DIV/0!

7 0.025 #DIV/0!

10 0.03 #DIV/0!

Page 30
 Milling

Approach length CT No of Holes Total CT

1.7272 0.143 8 1.14

2.794 0.168 8 1.34

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 2.49

1.1303 0.259 4 1.04

2.7305 0.206 4 0.83

1.4224 0.224 7 1.57

1.4224 0.30 7 2.09

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 5.52

1.7907 0.501 7 3.51

1.7272 0.470 2 0.94

2.794 0.171 2 0.34

0 #DIV/0!

Page 31
 Milling

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 4.79

1.7907 0.212 7 1.49

2.9845 0.239 7 1.67

0 #DIV/0!

Total Cycle Time (min) 3.16

1.2065 2.157 1 2.16

1.7907 0.174 8 1.39

1.9304 0.249 4 1.00

3.6703 0.30 4 1.22

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 5.76

0 #DIV/0! #DIV/0!

0 #DIV/0! #DIV/0!

0 #DIV/0! #DIV/0!

0 #DIV/0! #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) #DIV/0!

3.175 0.290 2 0.58

Page 32
 Milling

0 #DIV/0!

Total Cycle Time (min) 0.58

3.5687 0.360 8 2.88

1.63195 0.607 2 1.21

2.0193 0.571 8 4.57

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 8.67

3.2639 0.270 2 0.54

1.63195 0.267 2 0.53

2.1463 0.337 2 0.67

Total Cycle Time (min) 1.75

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 0.00

3.5687 0.428 10 4.28

3.5687 0.485 8 3.88

2.0193 0.297 14 4.16

7.1374 0.78 2 1.56

Page 33
 Milling

1.63195 2.04 2 4.07

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 17.95

2.4638 0.467 2 0.93

4.445 0.639 2 1.28

3.302 0.40 1 0.40

5.9563 1.93 0.00

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 2.61

1.9812 0.162 16 2.59

1.7907 0.138 8 1.11

1.7272 0.172 11 1.89

2.9845 0.22 11 2.47

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 8.05

0 #DIV/0!

0 #DIV/0!

Page 34
 Milling

Total Cycle Time (min) 0.00

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 0.00

0 #DIV/0!

Total Cycle Time (min) 0.00

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

0 #DIV/0!

Total Cycle Time (min) 0.00

Page 35
 Cutting Parameters for mat.

Cutting Parameters for Milling

For HSS

S No RM Grade
Cutting Speed
Feed (mm/min)
(SF/min)

1 Aluminium 600.00

2 Brass 175.00

3 Delrin 400.00

4 Polucarbonate 300.00

5 SS (303) 80.00

6 Steel (4140) 70.00

Cutting Parameters for Drilling

For Drilling For Countersink

S No RM Grade
Cutting Speed Cutting Speed
(SF/min) (SF/min)

1 Aluminium 300.00 200

2 Brass 120.00 90

3 Delrin 150.00 100

4 Polucarbonate 240.00 160

5 SS (303) 50.00 35

6 Steel (4140) 90.00 60

Page 36
 Cutting Parameters for mat.

7 Bronze (High Tensile) 100.00

8 Cast Iron (Soft) 100.00

9 Cast Iron (Med. Hard) 80.00

10 Cast Iron (High Hard) 20.00

11 Hastelloy 20.00

12 Inconel 25.00

13 Magnesium & Its Alloys 300.00

14 Monel 25.00

15 High Nickel Steel 50.00

16 Mild Steel (0.2 to 0.3 C) 100.00

17 Steel (0.4 to 0.5 C) 60.00

18 40.00
Tool Steel

19 Forgings 40.00

20 Steel Alloys (300 – 400 Brinell) 30.00

21 Heat Treated Steel (35 – 40 Rockwell C) 20.00

22 Heat Treated Steel (40 – 45 Rockwell C) 20.00

23 Heat Treated Steel (45 – 50 Rockwell C) 15.00

24 Heat Treated Steel (50 – 55 Rockwell C) 15.00

25 Stainless Steel Free Machining 40.00

26 Stainless Steel Work hardened 20.00

27 Titanium Alloys 20.00

Cutting Parameters for Drilling

Page 37
 Cutting Parameters for mat.

Tool dia 0.125” to

Tool dia <0.125”
0.25”
S No RM Grade
Cutting Feed Cutting Feed
(Inch/Rev) (Inch/Rev)

Milling
1 Aluminium 0.0020 0.0020

2 Brass 0.0010 0.0020

3 Delrin 0.0020 0.0020

4 Polucarbonate 0.0010 0.0030

5 SS (303) 0.0005 0.0010

6 Steel (4140) 0.0005 0.0005

7 Brass (Soft) 0.004 – 0.01

8 Brass (Hard) 0.004 – 0.01

9 Bronze (Soft) 0.004 – 0.01

10 Bronze (Hard) 0.004 – 0.01

11 Copper 0.004 – 0.01

12 Steel 100 BRN 0.004 – 0.00

13 Steel 200 BRN 0.004 – 0.00

14 Steel 300 BRN 0.003 – 0.00

15 Steel 400 BRN 0.002 – 0.00

16 Steel 500 BRN 0.001 – 0.00

17 Steel (Free machining) 0.002 – 0.00

18 Steel (hard) 0.002 – 0.00

19 Titanium (Soft) 0.002 – 0.00

Page 38
 Cutting Parameters for mat.

20 Titanium (Hard) 0.001 – 0.00

Drilling 0.0020 0.0040

Reaming 0.0050 0.0070

Page 39
 Cutting Parameters for mat.

Table feed (fm) = fxNxn

F – feed from chart

N – Spindle speed n
– No.of teeth

Spindle speed= K * V / 3.142 * Dt

K=12 or 60000 or
1000
D – Cutter Dia V
– Cutting Speed

Cycle time= L + LA / fm

L – Length of
component LA
– Length allowance
fm – Table feed

Length allowance= Sq.rt t(D-t)

D – Cutter Dia
t – Depth of cut

MRR= fm x W x t

Page 40
 Cutting Parameters for mat.

Milling

For Carbide

Cutting Speed (SF/min) Feed (mm/min)

800.00

175.00

800.00

500.00

300.00

350.00

Drilling

For Tapping
For Reamer
(HSS Tape)

Cutting Speed
Cutting Speed (SF/min)
(SF/min)

70-90 and 50-70 for

150.00
Al Aly

66.00 60-100

75.00 100

120.00 100

25.00 35

45.00 35

Page 41
 Cutting Parameters for mat.

30-40

60-80

50-60

30-60

15-30

20-40

50-70

10-12

50-70

30-50

20-40

20-30

15-25

15-25

10-15

10-20

15-25

60-100

ers for Drilling

Page 42
 Cutting Parameters for mat.

Tool dia 0.25” to Tool dia 0.5” to

0.50” 1.0”

Cutting Feed
Cutting Feed (Inch/Rev)
(Inch/Rev)

ng
0.0050 0.0060

0.0020 0.0040

0.0050 0.0060

0.0060 0.0080

0.0020 0.0030

0.0010 0.0020

0.004 – 0.012

0.004 – 0.010

0.004 – 0.012

0.004 – 0.010

0.004 – 0.012

0.004 – 0.006

0.004 – 0.005

0.003 – 0.004

0.002 – 0.003

0.001 – 0.002

0.002 – 0.005

0.002 – 0.004

0.002 – 0.005

Page 43
 Cutting Parameters for mat.

0.001 – 0.003

0.0050 0.0100

0.0090 0.0120

Page 44
S No Process Term Unit Formula

40I / (Tm^1.23)
Metal Removal I= Current in Amphere
1 Electrical Discharge Machining Rate CC/Min Tm=Melting temperature of work piece in °C
Metal Removal
2 Chemical Machining Rate MM/Min 0.0025 to 0.1

C*I* h
C= specific (material) removal rate (e.g.,0.2052
cm3/amp-min for nickel);
I= current (amp);
h= current efficiency (90–100%)
3 Electro-Chemical Machining CC/Min)
4

Metal removal
Rate (mm^3 / Tolerance
S No Process Name Min) (mm) Surface Finish CLA (Microns)
1 Ultrasonic Machining 300 0.0075 0.2-0.5
2 Abrasive Jet Machining 0.8 0.05 0.5-1.2
3 Electro Chemical Machining 1500 0.05 0.1-2.5
4 Chemical Machining 15 0.05 0.4-2.5
5 Electrical Discharge Machining 800 0.015 0.2-12.5
6 Electron Beam Machining 1.6 0.025 0.4-2.5
7 Laser Beam Machining 0.1 0.025 0.4-1.25
8 Plasma Arc Machining 75000 0.125 Rough
9 Milling 50000 0.05 0.4-5.0

1500000
1000
16.6666667
 Formula Remarks

mphere The volume of the material removed per spark discharge

mperature of work piece in °C is typically in the range of 10-6 to 10-6 mm3

• High surface finish (up to 25 µm in) can be achieved by ECM

process.
• Complex geometrical shapes in high-strength materials
terial) removal rate (e.g.,0.2052 particularly in the aerospace industry for the mass production
or nickel); of turbine blades, jet-engine parts and nozzles can be
); machined repeatedly and accurately.
ency (90–100%) • Deep holes can be made by this process.

600

Surface Corner
Damage Depth Radius Power
e Finish CLA (Microns) (microns) (mm) (watts)
0.2-0.5 25 0.025 2400
0.5-1.2 2.5 0.1
0.1-2.5 5 0.025 100000
0.4-2.5 50 0.125
0.2-12.5 125 0.025 2700
0.4-2.5 250 2.5 150
0.4-1.25 125 2.5 2
Rough 500 - 50000
0.4-5.0 25 0.05 3000

3.5
2100
0.28
117.6
85
85
1200
3503
4204