G-Wizard Machinists Calculator

A Quick Feeds and Speeds Course

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All Machinists Know the Basics

RPM = SFM * 4 / Cutter Diameter Feed Rate = RPM * Chip Load * Teeth Isnt That Good Enough???

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4 Problems
1. Tables Are Worst Case Estimates 2. Chip Thinning 3. Compensating for Odd Shapes 4. Tool Rigidity Classic Formulas Dont Consider All the Variables

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#1 Tables are Worst Case Estimates

Only a Few Variables: Full Range of Tool Diameter, Depth of Cut, Width of Cut, Materials, etc. No Interpolation No Idea of Coolant or Other Conditions What About Micro-Milling? Is Manufacturer Pushing Tool Life or MRR? Have to Assume Worst Case

HSM Toolpaths can go 3-5x Faster

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#2 Chip Thinning
Chip Thinning:

Simple formulas assume the red chip

The blue chip is reality.

You have to feed faster to get to the recommended chipload!

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Irony: Babying the Cut is Bad For Cutter Life!

Think of the Cutter Edge Radius Versus the Chip Thickness:

Radius <= Chip Thickness: Shearing Cut

Radius > Chip Thickness: Rubbing! - Chip pushed under not over - Rubbing = Heat = Poor Tool Life Shallow Cuts w/o Chip Thinning Adjustment Often Lead to Rubbing!
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#3 Compensating for Odd Shapes

Not all cutters are nice and square in profile Lead Angle Changes Feeds & Speeds Ballnose Changes Feeds & Speeds
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#4 Tool Deflection
All tools deflect, its about how much Roughing: > 0.001 = Onset of Chatter Finishing: < 0.0002 for Accuracy and Finish
Whats the Impact of HP on Tooling & Machine?
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Optimizing Feeds and Speeds is About Mastering More Variables

Hard to do by hand!
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So We Use a Calculator!

Lets See How With G-Wizard

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For More Information

Try the CNCCookbook Milling Feeds and Speeds Cookbook! www.cnccookbook.com

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