Titanium is an amazing material with some truly outstanding properties. It has a very high strength, is lightweight, is resistant to corrosion and chemicals, and can even maintain its strength when exposed to incredibly high temperatures.

Apr 3, 2024 — A deformed bar is a type of steel reinforcing bar that is designed to be deformed by mechanical or hydraulic means before installation.

SpeedsandFeeds chart

Imagine the cutting tool as a rolling ring or cylinder. The distance traveled in one revolution times rpm is its surface speed. If the circle above had a diameter of 3.82", the circumference would be 12". As a result, every revolution would produce a linear distance of 1', and a spindle speed of 100 rpm would be a cutting speed of 100 sfm.

Machining titanium requires careful temperature management. One of the most obvious ways to keep the workpiece and tooling cool is to apply consistent, high-pressure coolant directed to the cut area. Blasting the chips out of the cut area also keeps them from adhering to your machining tools.

Any manufacturing process in which metal is processed or machined such that the workpiece is given a new shape. Broadly defined, the term includes processes such as design and layout, heat-treating, material handling and inspection.

Value that refers to how far the workpiece or cutter advances linearly in 1 minute, defined as: ipm = ipt 5 number of effective teeth 5 rpm. Also known as the table feed or machine feed.

What is chip load? When milling, it is the amount of material that the cutting edge removes each time it rotates. When turning, it is the distance the part moves in one revolution while engaged with the tool. It is sometimes referred to as chip thickness, which is sort of true. Chip thickness can change when other parameters like radial DOC or the tool’s lead angle change.

While the tool or part is spinning, the machine must know how fast to travel while the cutter is engaged in the workpiece. Feed rate is the term that describes the traverse rate while cutting.

Lastly, depending on the design of the part, the elastic behavior of titanium can also make unsupported portions of a workpiece elastically deform out of position. The part bends away from the forces created by cutting tools, then returns to its normal position after the cutting tool passes, creating final parts that are out of tolerance.

Titanium is already prone to causing tool chatter, so anything you can do reduce vibration will make machining titanium easier. Ensure parts are well-supported and secured to prevent deflection in the workpiece. Use high-quality CNC machines with very stiff tooling arrangements. You can even consider using shorter cutting tools to reduce tool deflection.

Shrink fit holder with thermal contraction capability applies 360º uniform pressure onto the cutting tool shank along the entire length of bore. Shrink fit ...

Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes. The engine lathe consists of a headstock and spindle, tailstock, bed, carriage (complete with apron) and cross slides. Features include gear- (speed) and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines. Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces (instruments, watches), normally without a power feed. Models are typically designated according to their “swing,” or the largest-diameter workpiece that can be rotated; bed length, or the distance between centers; and horsepower generated. See turning machine.

Another way to consider this concept is to think about the distance the 1" tool would travel were it to make 382 revolutions across the shop floor. In that scenario, it would travel 100'; do it in 60 seconds and it would be traveling 100 sfm.

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As if that wasn’t enough, the low modulus of elasticity of titanium compared to its high strength makes it a “gummy” material to machine and can lead to severe chatter. This can result in galling of cut titanium, which adheres to tooling. Additionally, chatter and titanium’s springback effect at the cut location create poor machining conditions. These hurdles can further increase tool wear and can compromise finished surface quality.

Value that refers to how far the workpiece or cutter advances linearly in 1 minute, defined as: ipm = ipt 5 number of effective teeth 5 rpm. Also known as the table feed or machine feed.

Cuttingspeedformula

Toolmakers recommend cutting speeds for different types of workpiece materials. When a toolmaker suggests 100 sfm, it is indicating the outside surface of the rotating tool should travel at a rate of speed equal to 100 linear feet per minute. If the tool has a circumference (diameter × π) of 12", it would need to rotate at 100 rpm to achieve 100 sfm.

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Notice the vertical lines, called tool marks, on the outside of the part being turned. As the feed rate increases, the distance between the lines also increases. The chip thickness is roughly equal to the feed.

Milling cutter held by its shank that cuts on its periphery and, if so configured, on its free end. Takes a variety of shapes (single- and double-end, roughing, ballnose and cup-end) and sizes (stub, medium, long and extra-long). Also comes with differing numbers of flutes.

There is no singular property that makes titanium harder to machine than other materials. Instead, a combination of different properties work together to make most conventional machining tactics ineffective. By understanding what these challenges are, metallurgists and machinists can find solutions processing solutions that lead to high-quality machined titanium parts.

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Feedper tooth formula

Just remember that titanium alloys require careful machining, which must be carried out by trained experts. In contrast to free machining metals like Brass C360 or Steel SS416, working with titanium requires expertise, patience, and the correct tools.

Overall, machinists should choose high-quality tools designed for use with titanium, and they should frequently inspect and replace dull tools. Also consider using a smaller diameter tool with a larger number of cutting edges. This helps to maintain metal removal rates while reducing heat accumulation.

Chip load recommendations for turning operations are most often given in thousandths of an inch per revolution, or feed per rev. This is the distance the tool advances each time the part com-pletes one rotation.

The challenges of titanium machining are enough to make many machine shops wary of working with this advanced material. But its outstanding properties mean more and more product designers are looking to have quality parts made from titanium. Luckily, expert machinists and tooling suppliers have come up with a few key ways to make machining titanium at least a little bit easier.

So what is this telling us? Let’s say a 1"-dia. tool must run at 100 sfm. Based on the equation, that tool must turn at 382 rpm to achieve 100 sfm: 100 ÷ 1 × 3.82 = 382.

Lathes are different, of course, because the workpiece rotates instead of the cutter. Because the formula for cutting speed is dependent on diameter, as the diameter of the workpiece decreases, rpm must increase to maintain a constant surface speed. After each circular cut on the lathe, the workpiece OD decreases or the ID increases, and it is necessary for the rpm of the part to increase to maintain the desired cutting speed. As a result, CNC manufacturers developed the constant surface footage feature for lathe controls. This feature allows the programmer to input the desired cutting speed in sfm or m/min. and the control calculates the proper rpm for the changing diameter.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

This article will help you understand the challenges of machining titanium and some tips on how to machine titanium more effectively. We’ve also assembled a list of some of the best titanium grades for machining applications.

Unfortunately, some of the properties that make it so unique and valuable to product designers also make machining titanium incredibly difficult.

With different alloying elements come different mechanical properties for each titanium grade, meaning you can pick just the right titanium alloy for your application. Check out the following table to discover more about each alloy and to find out about it’s relative machinability!

Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.

Cutting speed calculations might well be the most important ones. They are easy to use and, with a little explanation, easy to understand. The cutting speed of a tool is expressed in surface feet per minute (sfm) or surface meters per minute (m/min.). Similar to mph for a car, sfm is the linear distance a cutting tool travels per minute. To get a better sense of scale, 300 sfm, for example, converts to 3.4 mph.

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Surface feet per minute, chip load, undeformed chip thickness and chip thinning are familiar shop terms. Over the last few weeks, however, several occurrences in our shop have made me realize there are a lot of metalworking professionals who don’t understand these terms and the calculations that go along with them. Whether you work at a small job shop or a large contract manufacturer, it is important to understand cutting tool calculations and how to use them to help drive significant efficiency gains.

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Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.

Here is where things get interesting, because by changing the values in the formula, the relationships of the different variables become evident. Try applying a 2" tool instead of the 1" tool. What happens? The rpm and feed rate decrease by half.

Tangential velocity on the surface of the tool or workpiece at the cutting interface. The formula for cutting speed (sfm) is tool diameter 5 0.26 5 spindle speed (rpm). The formula for feed per tooth (fpt) is table feed (ipm)/number of flutes/spindle speed (rpm). The formula for spindle speed (rpm) is cutting speed (sfm) 5 3.82/tool diameter. The formula for table feed (ipm) is feed per tooth (ftp) 5 number of tool flutes 5 spindle speed (rpm).

If you want expert support from a vendor you can trust, look no further than the CNC machining services offered by Gensun for your next titanium project.

Carbon fiber reinforced polymers (CFRP), or carbon fiber composites, are made by combining carbon fiber with a resin, such as vinyl ester or epoxy, ...

Feedrate formula

Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.

Jul 23, 2018 — Thread pitch is the term used to calculate the difference between two threads. For metric fasteners, the thread pitch is used in place of TPI.

Cutting speeds are published in sfm because the ideal cutting speed for a particular family of tools will, in theory, be the same no matter the size of the tool. The engineer, programmer or machinist is expected to calculate the rpm needed to produce the proper cutting speed for each selected tool.

The following equation is used to calculate spindle speed: rpm = sfm ÷ diameter × 3.82, where diameter is the cutting tool diameter or the part diameter on a lathe in inches, and 3.82 is a constant that comes from an algebraic simplifica-tion of the more complex formula: rpm = (sfm × 12) ÷ (diameter × π).

As you may have noticed, choosing the most suitable titanium for your product depends on the properties and applications you want. If you are trying to develop products for medical applications, you may want to choose the grade 23 titanium. Alternatively, if you are looking for a piece with excellent performance at elevated temperatures, you should consider working with grade 6 titanium.

Feedrate formula for milling

With titanium it’s also important to be very intentional about feed rates, spindle speeds, and chip loads. This means preventing excessive strain on tooling and equipment while also avoiding lingering in the same location for too long. It’s also worth evaluating whether a different cutting approach, like increasing axial cut depth while reducing radial engagement, could improve cutting efficiency and reduce machining temperatures.

About the Author: Christopher Tate is senior advanced manufacturing engineering for Milwaukee Electric Tool Corp., Brookfield, Wis. He is based at the company’s manufacturing plant in Jackson, Miss. He has 19 years of experience in the metalworking industry and holds a Master of Science and Bachelor of Science from Mississippi State University. E-mail: chris23tate@gmail.com.

The evolution of CNC machining has been marked by significant technological advancements. From the early days of punch tape and rudimentary programming, CNC machining has evolved to incorporate sophisticated software and high-speed, multi-axis machines. In recent...

Because the tool diameter is measured in inches, the “feet” in sfm must be converted to inches, and because there are 12 inches in a foot, multiply sfm by 12. In addition, the circumference of the tool is found by multiplying the tool diameter by π, or 3.14 to simplify. The result is: rpm = (sfm × 12) ÷ (diameter × π) = (sfm ÷ diameter) × (12 ÷ π) = (sfm ÷ diameter) × 3.82.

Feedrate formula for turning

What rpm and feed rate should be programmed for a 4-flute, 1" endmill, running at a recommended cutting speed of 350 sfm and a recommended chip load of 0.005 inch per tooth (ipt)? Using the equation, rpm = sfm ÷ diameter × 3.82 = 350 ÷ 1.0 × 3.82 = 1,337, the feed rate = rpm × no. of flutes × chip load = 1,337 × 4 × 0.005 = 26.74 ipm.

With the growing popularity of titanium, tool designers are coming up with unique solutions for improving the machinability of titanium. Advanced materials, like heat-resistant titanium aluminum nitride (TiAlN) or titanium carbo-nitride (TiCN) coated tooling, can extend tool lifetimes. Meanwhile tooling with uneven spacing between cutting edges can disrupt the constructive interference that leads to tool chatter.

Milling speedsandfeeds Chart

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Angle between the side-cutting edge and the projected side of the tool shank or holder, which leads the cutting tool into the workpiece.

One of the biggest obstacles to machining titanium is keeping everything cool. Titanium’s low thermal conductivity makes the metal workpiece rapidly accumulate heat at the tooling location. This increases the wear on machining tools and has the secondary effect of hardening the titanium, which then further exacerbates the tool wear. If not addressed, this can detrimentally affect the quality of cut surfaces.

Understanding these relationships and applying some creative thought can provide significant gains in efficiency. I will discuss how to take advantage of these relationships in my next column. CTE

Toolmakers publish chip load recommendations along with cutting speed recommendations and express them in thousandths of an inch (millimeter for metric units). For milling and drilling operations, chip load is expressed in thousandths of an inch per flute. Flutes, teeth and cutting edges all describe the same thing and there must be at least one, but, in theory, there is no limit to the number a tool can have.

Feed rate for milling is usually expressed in inches per minute (ipm) and calculated using: ipm = rpm × no. of flutes × chip load.

Due to the increasing demand for titanium, several machinable grades have been developed in the industry. They are differentiated by the percentages of pure titanium and other elements they contain, including elements like oxygen, palladium, nickel, or molybdenum.

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CNC milling is a CNC process that involves the use of rotating cutters to remove portions of a block of material (or workpiece) till the desired custom shape (or feature) is made. It allows manufacturers to create intricate parts accurately while meeting tight...