Cutting Data | YCK2020
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Tables on the
following pages provide basic speed, feed and cutting data for some of the
materials commonly used for prototypes. Use the tool manufacturer's data
instead whenever it is available.
Mill Cutting Speeds (SFM) surface ft/min
Table 3.5: Milling Speed Data (SFM) |
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Mill Cutting Speeds (SFM) surface ft/min |
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Material |
HSS |
Carbide |
Aluminum |
600 |
800 |
Brass |
175 |
175 |
Delrin |
400 |
800 |
Polycarbonate |
300 |
500 |
Stainless Steel (303) |
80 |
300 |
Steel (4140) |
70 |
350 |
Table 3.6: Drill Cycles Speed Data (SFM) |
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Drill Cutting Speeds (SFM) surface ft/min |
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Material |
Drilling |
C-Sink |
Reamer |
Tap |
Aluminum |
300 |
200 |
150 |
100 |
Brass |
120 |
90 |
66 |
100 |
Delrin |
150 |
100 |
75 |
100 |
Polycarbonate |
240 |
160 |
120 |
100 |
Stainless Steel (303) |
50 |
35 |
25 |
35 |
Steel (4140) |
90 |
60 |
45 |
35 |
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Never use tools that have been used to machine metal to cut plastic. The sharp edge of the tool will be compromised and cutting performance and finish will suffer. A good practice is to keep two sets of tools: one for plastic and one for metal. High-speed steel cutters work best for plastics. Carbide cutters work better for aluminum and other metals. |
Table 3.7: Feed Data (IPR) |
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Cutting Feeds (IPR) in/rev |
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Operation |
Tool Diameter Range (in) |
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|
<.125 |
.125-.25 |
.25-.5 |
.5-1. |
>1. |
Milling |
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Aluminum |
.002 |
.002 |
.005 |
.006 |
.007 |
Brass |
.001 |
.002 |
.002 |
.004 |
.005 |
Delrin |
.002 |
.002 |
.005 |
.006 |
.007 |
Polycarbonate |
.001 |
.003 |
.006 |
.008 |
.009 |
Stainless Steel (303) |
.0005 |
.001 |
.002 |
.003 |
.004 |
Steel (4140) |
.0005 |
.0005 |
.001 |
.002 |
.003 |
|
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Drilling |
.002 |
.004 |
.005 |
.010 |
.015 |
|
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Reaming |
.005 |
.007 |
.009 |
.012 |
.015 |
Best
Practice Machining Parameters
Best practice
machining parameters for prototype and short-production milling are different
than for mass production. Production machining is obsessed with minimizing run
time and maximizing tool life because even small improvements per part can
result in significant cost savings.
Prototype and
short run production seeks to maximize reliability. Obviously, it does not make
sense to risk breaking a tool or scrapping a part trying to save a few seconds
if only making a few parts.
Tables 3.8 and
3.9 on the following pages list recommended machining parameters for
prototypes. The values are relatively conservative and work well for materials
and tool types listed on the previous pages.
For materials
or tools not listed, consult cutting data from the tool manufacturer.
Table 3.8: Machining Parameters |
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Recommended Machining Parameters |
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Operation |
Parameter |
Value |
All |
Clearance Height |
1.0 inch |
All |
Feed Height |
.1 inches |
All |
Rapid Height |
As needed to clear clamps and fixtures |
Mill (Roughing) |
Stepover (XY) |
50-80% of tool dia. |
Mill (Roughing) |
Stepdown (Z) |
25-50% of tool dia. |
Drill |
Peck Increment |
.05 inches |
Spot Drill |
Dwell |
.5 seconds |
Table 3.9: Stock Allowances |
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Stock Finish Allowances (inches) |
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Operation |
Tool Diameter Range (in) |
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|
<.125 |
.125-.25 |
.25-.5 |
.5-1. |
>1. |
Milling (XY) |
.001 |
.005 |
.015 |
.020 |
.020 |
Milling (Z) |
.001 |
.002 |
.005 |
.005 |
.005 |
Reaming |
.005 |
.010 |
.012 |
.020 |
.030 |
Troubleshooting
Speed/Feed Problems
Do not make the
mistake of thinking that the only option when encountering a machining problem
is to reduce feed rate. Sometimes that is the worst thing to do and decreasing
speed and increasing feed may be a better option.
Be methodical.
When a problem occurs, stop. Analyze what is happening, draw on all available
resources, and then devise a solution to correct the problem. The Machinery's
Handbook (Industrial Press Inc, 2008, New York, NY, ISBN: 978-8311-2800-5) contains
extensive information about diagnosing and correcting cutting tool problems.
This book is an essential reference for anyone using machine tools.