Milling parameters
Calculations
n = Revolutions per minute (rpm) z = Number of teeth
vc = Cutting speed (m/min) fz = Tooth feed (mm/tooth)
d = Tool diameter in millimeters (mm) vf = Feed rate (mm/min)
The end mill speed is calculated with the following formula:
n [rpm] = (vc [m/min] *1000) / 3.14 * ø d1 [mm])
Example calculation:
vc = 500 m/min (selected from chart)
d = ø 8 mm
19904 rpm = (500 *1000) / (3.14 * 8)
If the maximum speed of the milling motor is lower than the calculated value, the maximum speed of the milling motor
needs to be inserted into the formula for the feed calculation.
The end mill feed rate is calculated with the following formula:
vf = n * z * fz
Example calculation for aluminum (wrought alloy) with 8 mm end mill 2-flute:
n = 15923 rpm from upper formula
fz = 0,064 from chart
z=2
2547,77 mm/min = 19904 * 2 * 0,064
Benchmark for Speed and Feed
End Mill Diamater
ø Cutting
Speed ø 1 mm ø 2 mm ø 3 mm ø 4 mm ø 5 mm ø 6 mm ø 8 mm ø 10 mm ø 12 mm
m/min.*
Feed Rate in mm / Tooth / Revolution
Cast Aluminum
200 0,010 0,010 0,010 0,015 0,015 0,025 0,030 0,038 0,050
> 6 % Si
Wrought Aluminum
500 0,010 0,020 0,025 0,050 0,050 0,050 0,064 0,080 0,100
Alloy
Soft Plastic 600 0,025 0,030 0,035 0,045 0,065 0,090 0,100 0,200 0,300
Hard Plastic 550 0,015 0,020 0,025 0,050 0,060 0,080 0,089 0,100 0,150
Hard Wood 450 0,020 0,025 0,030 0,055 0,065 0,085 0,095 0,095 0,155
Soft Wood 500 0,025 0,030 0,035 0,060 0,070 0,090 0,100 0,110 0,160
MDF 450 0,050 0,070 0,100 0,150 0,200 0,300 0,400 0,500 0,600
Brass, Copper,
365 0,015 0,020 0,025 0,025 0,030 0,050 0,056 0,065 0,080
Bronze
Steel 75 0,010 0,010 0,012 0,025 0,030 0,038 0,045 0,050 0,080
*The stated cutting speeds are average values. In result of the milling process and the type of end mill adjustments might be necessary.
Roughing: Reduction of up to 25 % – Finishing: Increase of up to 25 % – HSS end mill: Reduction of up to 50 % (hard materials) – VHM end mill: Increase of up to 25 %
Practical Tip
Immersion Depth:
While milling a groove we recommend the following immersion depth:
Material D-Series Q-Series
Non-ferrous Metals up to a diameter up to a diameter
0,25 times higher 0,5 times higher
Wood, Plastics up to a diamete up to a diameter
1,5 times higher 2 times higher
Rigid Foam up to a diameter up to a diameter
3,5 times higher 5 times higher
During contour milling we recommend a lateral infeed of approx.
25 % of the end mill diameter while applying 100 % immersion depth.
The immersion depth is conditional to the milling motor, the
structure and the stability of the machine. This means a reduction
of the values is required, when using a less powerful and / or lighter
milling motor.
End Mill Length Selection:
To avoid increasing vibration of the end mill we recommend clamping the bit as short as possible or as long as necessary.
Right Wrong
Cooling / Lubricating:
The cooling of non-ferrous metals occurs in best case with a lubrication system in combination with lubricant.
Furthermore the lubricating improves the surface quality and the service life of the tool.
Lubricating with a soap solution is suitable on acrylic glass. This improves an excellent surface.
Downcut Milling:
In downcut milling, the end mill pulls itself into the workpiece,
which can lead to the gantry or the Z-axis being pulled uncontrolled
(backlash of lead screw) in the direction of the workpiece during the
removal of larger chips. This causes a less precise milling pattern
and can even result in the breakage of the end mill, if the chip buil-
ding is too large.
Assuming backlash-free ball screws are used, the downcut is
preferred over the upcut milling.
Upcut Milling:
During upcut milling, the end mill pushes away from the workpiece,
which, when only removing little chips, quickly causes the cutting
edge to push out of the workpiece. This leads to chatter marks which
create an unclean surface and reduce the endurance of the end mill.
The upcut milling is favored on machines with threaded lead screws
which contain backlash.
Relief-grinded End Mills:
The maximum possible infeed is usually reduced to the spiral length of the end mill, otherwise the shank will rub on the
workpiece. Due to the relief-grinded shank, depths over several infeeds up to the maximum effective lengths are possible,
thus, exceeding the spiral length.
Lubrication System 20-50 ml /h:
Dependence of lubrication system Suitability of lubrication system for
on production process cutting materials
Milling Cu Alloy
Drilling Al Casting Alloy
Grinding Steel ferritic
Lapping Mg Alloy
Turning Wrought Aluminum Alloy
Grating Pearlitic
Honing Cast Iron
Stainless Steels
increasing lube increasing material qualification
