The strength of the cutting tool plays a role in the allowable cutting speeds for machining operations. For example, you can use high cutting speeds when machining with a cutting tool made of high-strength materials like diamond and carbon boron nitride, whereas tools made of high-speed steel demand lower cutting speeds.

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To help you understand these two terms, let’s consider a simple analogy of a car moving at a linear speed of 60 km/hr with wheels rotating at 500 rpm. You’d agree that the wheels’ diameter and rotation are responsible for the car’s movement along a paved road. But when describing the vehicle’s speed to a friend, you’d explain it in terms of kilometers per hour.

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Still considering the car analogy, a wheel rotating at higher RPMs will likely consume more power and wear more quickly than wheels turning at lower RPMs. This wear is due to the friction and high temperatures between the tires and the road. Similarly, cutting speed affects the tool life, cutting temperature, and power consumption.

Now that you understand the differences between feed rate vs. cutting speed, you’d agree that these two machining parameters are important during CNC machining. However, even after you choose the ideal cutting speed and feeds, the success of your project also depends on the machine shop you work with.

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Cutting speed can be compared to the linear velocity of the car, which depends on the wheels’ diameter and RPM. It measures the linear distance moved by the cutting tool against the machined part at a given time. Cutting speed is measured in millimeters per minute (mm/min), meters per minute (m/min), or feet per minute (ft/min).

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In contrast, we can compare the feed rate to the wheels’ rotation in the car analogy. Feed rate is simply the distance the tool travels during one revolution of the part. We measure it in inch per revolution (inch/rev) or millimeter per revolution (mm/rev).

But what is cutting speed, and how does it differ from feed rate? And how do these machining parameters contribute to the success of your manufacturing project? This article answers all of these questions and more.

Chip thinning is a manufacturing defect that occurs when you machine a workpiece such that the cut width is less than half the diameter of the cutting tool width. This reduces the chip load (the size or amount of material removed by the cutting tool per revolution), causing greater lead times.

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Feed rates also affect the tool life and power consumption during machining, but their effects are usually negligible compared to cutting force. Instead, feed rates are more likely to affect the machining time and surface finish of the machined part.

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When milling or drilling, or creating a tool path for a CNC machine the feed rate must be determined. Materials have rated surface speeds for a given type of cutter. The harder the material the slower the speed. Given the diameter of the tool and the surface speed, the RPMs of the spindle can be calculated. Then if the tooth load for the cutter is know, and the number of teeth, the feed rate can be determined.

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To determine the optimum cutting speed for your machining project, you need to consider the workpiece hardness and the strength of the cutting tool.

As a rule, the harder the workpiece material, the slower the cutting speed you should implement during machining. For example, materials like titanium will require a lower cutting speed compared to steel.

Hardness describes the resistance of a material to deformation induced by abrasion, indentation, or scratching. Harder workpiece materials demand special attention during machining since they can easily reduce the performance life of cutting tools.

One way to reduce the effect of chip thinning is to machine your workpiece at high feed rates. Doing this helps to improve your productivity and tool life.