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Thread: Milling Feeds and Speeds Calculator

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    Milling Feeds and Speeds Calculator

    Hello,

    Anyone know of a good (easy to use) and free machining calculator that I can download please. As I have looked at a few and well I think they have all been written by people that know about machining and are full of terms like: Surface Speed and Chip Load etc. These I guess are fine for people that are experienced machinists and have material specification and HP tooth loadings at there finger tips but I do not.

    Hence I am looking for a “Feeds and Speeds Calculator” for dummies, where you simple select the material type, machine type (mini router, small X2, medium X5, or two meter high Bridgport monster).


    Alternatively as I am a software developer that wants to do some light machining on wood, plastics and soft metals. I will write a free to all software application if someone out there that knows about the science of machining want to partner up with me. Basically all the user should need to do is to select the following:

    Machine Type.
    Material Type.
    Finish Quality: (Rough and Finish cut) ...Step Over...
    Tool: Size, Type, Material and Cutting Tips etc.

    Click the “Compute” button and out pops some table or even graph of recommended spindle speeds. Then click the spindle speed that fits with in the parameters of your machine and “hey presto” out pops the figures you need… Simple…..

    So anyone seen anything like this? Or are you interested in helping me write it (No Software development experience required)

    Many thanks IMK

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    Quote Originally Posted by IMK1230 View Post
    Hello,

    Anyone know of a good (easy to use) and free machining calculator that I can download please. As I have looked at a few and well I think they have all been written by people that know about machining and are full of terms like: Surface Speed and Chip Load etc. These I guess are fine for people that are experienced machinists and have material specification and HP tooth loadings at there finger tips but I do not.

    Hence I am looking for a “Feeds and Speeds Calculator” for dummies, where you simple select the material type, machine type (mini router, small X2, medium X5, or two meter high Bridgport monster).


    Alternatively as I am a software developer that wants to do some light machining on wood, plastics and soft metals. I will write a free to all software application if someone out there that knows about the science of machining want to partner up with me. Basically all the user should need to do is to select the following:

    Machine Type.
    Material Type.
    Finish Quality: (Rough and Finish cut) ...Step Over...
    Tool: Size, Type, Material and Cutting Tips etc.

    Click the “Compute” button and out pops some table or even graph of recommended spindle speeds. Then click the spindle speed that fits with in the parameters of your machine and “hey presto” out pops the figures you need… Simple…..

    So anyone seen anything like this? Or are you interested in helping me write it (No Software development experience required)

    Many thanks IMK
    You could learn what the words mean, they aren't that difficult. Surface speed refers to just that, the speed at which the surface of the cutter moves. The circumference of the cutter (Pi x diameter) multiplied by the RPM. There are plenty of tables of recommended surface speeds for various materials. The above equation is sometimes condensed to 4 times the surface speed divided by the cutter diameter. Look up your material in the chart plug in surface speed and diameter and you get spindle RPM.
    Chip load is the amount removed in a single bite, and depends on RPM, feed rate and number of flutes. It's not that difficult to work out either.



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    escott76 many thanks for your reply.

    But that was just the sort of reply I expect and really wanted to avoid. As I am sure you know the web is full of mis-information and techno babble and endless charts on site that contradict each other and forums where question are asked and none answers are returned.

    For example on another forum someone has asked:

    Question
    I was wondering about what chip load is.

    Reply
    You can determine your chip load or figure your speeds and rpm to target the proper chip load with the following formulae.
    Chip load = Feed rate / (RPM * # of Cutting Edges)
    Feed rate = RPM * Cutting Edges * Chip load
    RPM = Feed rate / (# of cutting edges * Chip load)
    Mmmmm I now know how to calculate it but I really still don’t know what its significance is and its relevance.

    So if you know and truly understand these concepts and know where to find reliable information on the web how about we combine our skills to develop a layman’s guide to milling.

    Again many thanks for your help

    IMK



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    Gold Member dertsap's Avatar
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    Quote Originally Posted by IMK1230 View Post
    Hello,


    Hence I am looking for a “Feeds and Speeds Calculator” for dummies, where you simple select the material type, machine type (mini router, small X2, medium X5, or two meter high Bridgport monster).

    its not as easy as that ,

    each company has its own specs on how fast their endmills should be ran in a particular material , most companies will give a chart showing the sfm for each material , talk to your tool retailer , other than that you'll only get other peoples guesses and they may be an educated guess but then maybe not

    A poet knows no boundary yet he is bound to the boundaries of ones own mind !! ........
    http://microcarve.microcarve.biz/


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    Community Moderator Al_The_Man's Avatar
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    If you send me an email address via P.M. I can send you one.
    Al.

    CNC, Mechatronics Integration and Custom Machine Design (Skype Avail).

    “Logic will get you from A to B. Imagination will take you everywhere.”
    Albert E.


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    Quote Originally Posted by dertsap View Post
    its not as easy as that ,

    each company has its own specs on how fast their endmills should be ran in a particular material , most companies will give a chart showing the sfm for each material , talk to your tool retailer , other than that you'll only get other peoples guesses and they may be an educated guess but then maybe not
    Yes it is that easy!

    We just need to find what easy is? and bring into the public domain a nice easy to use software package that is a good dummies guide.

    For example; yesterday I designed a 45mm dia. smiley face that is 3mm deep. I milled it out off hard plastic with a carbide 3mm bull mill with S & F that I have used before for other jobs on plastics. Then this morning I tried to mill it out of aluminium with S & F that I calculated from a site that published a list of material chips loads. And well somewhere during that third pass (0.5mm step) of the roughing cut the tool broke! Not a big expense but a delay in the job as I have to wait a few days now for a new tool and then what? Take a guess and half the F & S until the job no longer breaks tool. No, there has to be a better way of doing this! Somewhere out there is the machining knowledge base (man or woman) I am looking for to help put together the software tool that I seek.

    Again many thanks for your input.
    IMK



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    Gold Member dertsap's Avatar
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    Quote Originally Posted by IMK1230 View Post
    Yes it is that easy!

    We just need to find what easy is?
    IMK

    your going to need to do this for a while before you can understand

    have you looked at various manufacturers and compared sfm on the variety of materials with the variety of tools available
    have you taken into consideration the different coatings , helix's , grain and other tooling geometry's , all these things play a role in how these companies determine how fast the tools should run , this is why each manufacturer supplies a chart , manufacturer quality plays a big role in the determined speeds and feeds
    you may run a tool for weeks on a job then take a tool from another company and destroy it in minutes , its that simple
    you can create a calculator based on the lowest manufacturers values then at least you can create something that's on the safer side of dangerous , but then you'll destroy better tooling because they are not running at their proper speeds
    generally if you keep within the manufacturers specs then your tool will be safe under normal machining , but if you run above or below those specs your running the risk of disaster

    A poet knows no boundary yet he is bound to the boundaries of ones own mind !! ........
    http://microcarve.microcarve.biz/


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    Quote Originally Posted by dertsap View Post
    your going to need to do this for a while before you can understand

    have you looked at various manufacturers and compared sfm on the variety of materials with the variety of tools available
    have you taken into consideration the different coatings , helix's , grain and other tooling geometry's , all these things play a role in how these companies determine how fast the tools should run , this is why each manufacturer supplies a chart , manufacturer quality plays a big role in the determined speeds and feeds
    you may run a tool for weeks on a job then take a tool from another company and destroy it in minutes , its that simple
    you can create a calculator based on the lowest manufacturers values then at least you can create something that's on the safer side of dangerous , but then you'll destroy better tooling because they are not running at their proper speeds
    generally if you keep within the manufacturers specs then your tool will be safe under normal machining , but if you run above or below those specs your running the risk of disaster

    So here we are at the sort of impasse that I expect from the question I have asked.

    So let me ask you one more simple question please. You have an important job that needs to be done TODAY, and sitting in your tool draw is the only tools size shape for the job. Unfortunately for all of life reasons you can not get access to the tools precise specifications. So do you:

    (A) look at the specifications of three similar tools and take the ((a+b+c)/3) mean and get of with the job.

    Or.

    (B) Be pedantic and give up the job because you don’t have the precise specification.

    If you are an (A) person then I believe that you are the help that I need to push my project forward. If you are a (B) person then thank you very much for your input and I shall search on for Mr or Mrs (A)

    IMK



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    Quote Originally Posted by Al_The_Man View Post
    If you send me an email address via P.M. I can send you one.
    Al.

    Hello Al,

    And many thanks re my question and I have PM you as requested.

    IMK



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    Hi, being new to machining myself I cant help. BUT I can say that I would love to have the kind of tool you seem to want to develop.

    I have searched everywhere for some tool that just asks the type of material and the size and type of endmill and then tells you the dept of cut and feeds etc. you can use with that tool and that material.



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    Quote Originally Posted by daanmuller View Post
    Hi, being new to machining myself I cant help. BUT I can say that I would love to have the kind of tool you seem to want to develop.

    I have searched everywhere for some tool that just asks the type of material and the size and type of endmill and then tells you the dept of cut and feeds etc. you can use with that tool and that material.
    Hello daanmuller and many thanks for the reply.

    Yes it would be nice but I think there are (and as within all schools of engineering) there are those that wish to keep it a dark science so they can sound impressive when it comes to lowering themselves to talk to the great unwashed.

    As for me well my school is electronics and I don’t think I have such a vice as I always try to be constructive. Lets face it how many people understand the working of a TV, but the engineer did a great job of making it accessible to all.

    Anyway let us see what AL sends through as has some software he said he would send me. (See further down the posting) Ask him and he maybe really has something.

    Good luck in your quest.

    IMK



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    Quote Originally Posted by IMK1230 View Post
    Hello,

    Anyone know of a good (easy to use) and free machining calculator that I can download please. As I have looked at a few and well I think they have all been written by people that know about machining and are full of terms like: Surface Speed and Chip Load etc. These I guess are fine for people that are experienced machinists and have material specification and HP tooth loadings at there finger tips but I do not.

    Hence I am looking for a “Feeds and Speeds Calculator” for dummies, where you simple select the material type, machine type (mini router, small X2, medium X5, or two meter high Bridgport monster).


    Alternatively as I am a software developer that wants to do some light machining on wood, plastics and soft metals. I will write a free to all software application if someone out there that knows about the science of machining want to partner up with me. Basically all the user should need to do is to select the following:

    Machine Type.
    Material Type.
    Finish Quality: (Rough and Finish cut) ...Step Over...
    Tool: Size, Type, Material and Cutting Tips etc.

    Click the “Compute” button and out pops some table or even graph of recommended spindle speeds. Then click the spindle speed that fits with in the parameters of your machine and “hey presto” out pops the figures you need… Simple…..

    So anyone seen anything like this? Or are you interested in helping me write it (No Software development experience required)

    Many thanks IMK
    The Speed and Feed Wizard in Mach 3 is about as easy as a newbie can get it.
    They input their machines Max rpm so the calculations are based on their machine.
    The only "techno babble" they need to know is Chip Load Per Tooth.
    The thickness of a chip that is removed by one cutting edge of the tool.
    This is provided by the manufacturer of the endmill they wish to use such as this typical chart provides.
    "Machine Type" will only vary the DOC (Depth Of Cut) which most calculators don't provide because of the vast sizes and rigidity of the equipment out there.
    If someone can't be bothered to learn even the basics of machining then maybe this isn't the hobby for them.
    Hoss

    http://www.hossmachine.info - Gosh, you've... really got some nice toys here. - Roy Batty -- http://www.g0704.com - http://www.bf20.com - http://www.g0602.com


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