The calculator below shows the diameters and helix angle combinations, which yield the least vibrations for a given depth. (Read below why)

Since the diameter, helix angle, and flute count of the milling cutter can not be changed. We can find an optimal cut depth that will yield a constant cutting force:You can use our above calculator to find out this depth of cut. All the multiples of this depth will also yield constant force.When you machine with a constant force, you will get less vibrations, a better surface finish, and a longer too-life.You can also use this theory in another effective way. Suppose you have a mass-production job and must constantly machine at a certain depth. If you reverse the formulas, you can find specific combinations of diameter, flute count, and helix angles to yield constant force and smooth machining. The result will be non-standard figures. But it may be well worth designing and purchasing a special cutter according to these parameters for a mass-production job.You can use our above calculator to find out the optimal milling cutter geometry for your required depth of cut.Radial Depth of Cut (Cut Width)The Radial depth of cut is also called Stepover and Cut Width. It is designated by ae or RDOC.The maximum possible radial depth is the cutter’s diameter.When the radial depth is larger or equal to the cutter’s radius, the chip load is similar to the feed per tooth.The chip load is reduced for smaller cut widths because of the chip thinning effect. (See below)Chip Thinning EffectIn a milling operation, the Chip Thickness varies between the point of entry (A) and the Point of Exit (C).When the Radial Depth of Cut is greater or equal to the cutter’s radius, The maximum Chip thickness equals the Feed Per Tooth.When the radial depth of cut is smaller than the cutter’s radius (Point B), the maximum chip thickness gradually decreases even though the feed per tooth remains the same.This phenomenon is called Chip Thinning.Chip Thinning allows dramatic productivity gain since you can multiply the Feed by the Chip Thinning Factor (RCTF) while keeping the Chip Load within the recommended range! Learn more about it in our detailed guide about chip thinning\( \large RCTF = \)\( \huge \frac{1}{\sqrt{1-\left ( 1 – 2 \times \frac{Ae}{D} \right )^{2}}} \)Depth Of Cut Effects On MachiningIf we understand each effect, we can make informed decisions about changes in radial or axial depth of cut to solve the problem we have on hand. Assuming that the Cutting speed, spindle speed, cutter diameter, and feed are constant, let’s have a look at what changes in AE and AP are affecting.Productivity:The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

We saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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When it comes to the manufacturing of aerospace parts and custom fasteners, cross drilling is a common technique many use to complete manufacturing. Various applications use the technique of cross drilling, such as drilling holes in crankshafts for oiling purposes and cross drilling services for brass, aluminum, copper, mild steel and plastic. The use of cross drilling is also for inserting a roll or dowel pin to transfer rotary motion, such as driving a wheel, engaging a clutch, cam or other mechanical connection.

We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.

You can use our above calculator to find out this depth of cut. All the multiples of this depth will also yield constant force.When you machine with a constant force, you will get less vibrations, a better surface finish, and a longer too-life.You can also use this theory in another effective way. Suppose you have a mass-production job and must constantly machine at a certain depth. If you reverse the formulas, you can find specific combinations of diameter, flute count, and helix angles to yield constant force and smooth machining. The result will be non-standard figures. But it may be well worth designing and purchasing a special cutter according to these parameters for a mass-production job.You can use our above calculator to find out the optimal milling cutter geometry for your required depth of cut.Radial Depth of Cut (Cut Width)The Radial depth of cut is also called Stepover and Cut Width. It is designated by ae or RDOC.The maximum possible radial depth is the cutter’s diameter.When the radial depth is larger or equal to the cutter’s radius, the chip load is similar to the feed per tooth.The chip load is reduced for smaller cut widths because of the chip thinning effect. (See below)Chip Thinning EffectIn a milling operation, the Chip Thickness varies between the point of entry (A) and the Point of Exit (C).When the Radial Depth of Cut is greater or equal to the cutter’s radius, The maximum Chip thickness equals the Feed Per Tooth.When the radial depth of cut is smaller than the cutter’s radius (Point B), the maximum chip thickness gradually decreases even though the feed per tooth remains the same.This phenomenon is called Chip Thinning.Chip Thinning allows dramatic productivity gain since you can multiply the Feed by the Chip Thinning Factor (RCTF) while keeping the Chip Load within the recommended range! Learn more about it in our detailed guide about chip thinning\( \large RCTF = \)\( \huge \frac{1}{\sqrt{1-\left ( 1 – 2 \times \frac{Ae}{D} \right )^{2}}} \)Depth Of Cut Effects On MachiningIf we understand each effect, we can make informed decisions about changes in radial or axial depth of cut to solve the problem we have on hand. Assuming that the Cutting speed, spindle speed, cutter diameter, and feed are constant, let’s have a look at what changes in AE and AP are affecting.Productivity:The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

The better way of being sure that the hole is in the center is by using a cross drilling jig. Most of these jigs are based on the fact that a round object is being placed in a symmetrical V-shape then the center of the round piece lies above the vertex of the V. The only requirement is something to guide the drill bit. You do this by fitting the piece over the V. It has a hole in it to take either a part used to set it up or a part to take a drill bit. It then holds onto the bottom part using two slots, which means it can later be adjusted.

Chip Thinning allows dramatic productivity gain since you can multiply the Feed by the Chip Thinning Factor (RCTF) while keeping the Chip Load within the recommended range! Learn more about it in our detailed guide about chip thinning

However, specific combinations of diameters, number of flutes, helix angles, and depth of cut yield a constant contact length independent of the rotation angle, therefore, a constant force.

The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)

Cross drilling can affect the structural integrity of the rotors by creating stress-riser, which leads to crack propagation from the drilled holes. This may reduce the lifespan and reliability of the rotors, especially under heavy load or high temperature conditions. The use of cross drilling also reduces the mass of the rotors, which lowers their heat capacity and resistance to warping. When it comes to cross drilling, it needs to be done carefully and with proper chamfering and radius of the hole edges to minimize the risk of cracking.

If we understand each effect, we can make informed decisions about changes in radial or axial depth of cut to solve the problem we have on hand. Assuming that the Cutting speed, spindle speed, cutter diameter, and feed are constant, let’s have a look at what changes in AE and AP are affecting.Productivity:The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)

Depth of cutformula

The two parameters are interlinked, and finding the best value for each of them and the proportion between them is critical to achieving a balanced milling process (Productivity, Safe process, and tool-life)Table of ContentsAxial Depth of CutOptimal Depth CalculatorsRadial Depth of CutDepth Of Cut Effects On MachiningAxial Depth of Cut (Cut Depth)The Axia depth of cut is also called Stepdown and Cut depth.It is designated by ap or ADOC.The maximum possible depth depends mainly on the cutter’s diameter.For large diameter cutters (Above 3/4″, 20 mm), It is up to 4D (4 times the diameter).For small diameter cutters (Below 1/8″, 3 mm) it is up to 10D.Optimal Cut Depth CalculatorsThe typical (and wrong!) opinion is that the larger the depth, the more vibrations will be in the cut. However, there are optimized cut depths that create minimum vibrations.Optimal Depth of Cut CalculatorThe calculator below shows the cut depths (ap), which yield the least vibrations. (Read below why)Payment options Optimal Milling Cutter for a given DepthThe calculator below shows the diameters and helix angle combinations, which yield the least vibrations for a given depth. (Read below why)Payment options Reducing vibrations by optimizing the depth of cutThe cutting force during a milling operation depends on the depth of cut, chip load, raw material, cutting angles, and the total length of engagement between the cutting edges of the endmill and the material being cut. All the parameters stay constant throughout the operation except for cutting-edge engagement. The length of the helix, which is in contact with the material, varies as the cutter rotates.Therefore, a typical graph for the cutting forces acting on a solid carbide endmill as a function of time (or rotation angle) is like shown here.However, specific combinations of diameters, number of flutes, helix angles, and depth of cut yield a constant contact length independent of the rotation angle, therefore, a constant force.Since the diameter, helix angle, and flute count of the milling cutter can not be changed. We can find an optimal cut depth that will yield a constant cutting force:You can use our above calculator to find out this depth of cut. All the multiples of this depth will also yield constant force.When you machine with a constant force, you will get less vibrations, a better surface finish, and a longer too-life.You can also use this theory in another effective way. Suppose you have a mass-production job and must constantly machine at a certain depth. If you reverse the formulas, you can find specific combinations of diameter, flute count, and helix angles to yield constant force and smooth machining. The result will be non-standard figures. But it may be well worth designing and purchasing a special cutter according to these parameters for a mass-production job.You can use our above calculator to find out the optimal milling cutter geometry for your required depth of cut.Radial Depth of Cut (Cut Width)The Radial depth of cut is also called Stepover and Cut Width. It is designated by ae or RDOC.The maximum possible radial depth is the cutter’s diameter.When the radial depth is larger or equal to the cutter’s radius, the chip load is similar to the feed per tooth.The chip load is reduced for smaller cut widths because of the chip thinning effect. (See below)Chip Thinning EffectIn a milling operation, the Chip Thickness varies between the point of entry (A) and the Point of Exit (C).When the Radial Depth of Cut is greater or equal to the cutter’s radius, The maximum Chip thickness equals the Feed Per Tooth.When the radial depth of cut is smaller than the cutter’s radius (Point B), the maximum chip thickness gradually decreases even though the feed per tooth remains the same.This phenomenon is called Chip Thinning.Chip Thinning allows dramatic productivity gain since you can multiply the Feed by the Chip Thinning Factor (RCTF) while keeping the Chip Load within the recommended range! Learn more about it in our detailed guide about chip thinning\( \large RCTF = \)\( \huge \frac{1}{\sqrt{1-\left ( 1 – 2 \times \frac{Ae}{D} \right )^{2}}} \)Depth Of Cut Effects On MachiningIf we understand each effect, we can make informed decisions about changes in radial or axial depth of cut to solve the problem we have on hand. Assuming that the Cutting speed, spindle speed, cutter diameter, and feed are constant, let’s have a look at what changes in AE and AP are affecting.Productivity:The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

Therefore, a typical graph for the cutting forces acting on a solid carbide endmill as a function of time (or rotation angle) is like shown here.

Depth of cutformula for turning

We can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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Depth of cut definitionlathe

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Depth of cutin drilling

Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

There are nice benefits of using cross drilling for the manufacturing of custom fasteners. Let's take a look at these benefits.

In milling, the depth of cut is two-dimensional. The Radial depth of cut (AE or RDOC) is the length that the tool engages a workpiece perpendicular to its axis direction. The Axial depth of cut (AP or ADOC) is the length in its axis direction. They are both measured perpendicular to the table feed direction.

Depth of cut definitionlathe machine

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Precise cross drilling is needed when a handle is to be held onto a shaft with a tapered pin. Of course, the tapered pin has the property that it will not fall out. However, it can incorrectly give the impression that the hole in the handle and the hole in the shaft will only ever be mated together one way round. And generally, there may be times when it is useful to put the handle on the other way round. Using a cross drill accomplishes these aspects.

Depth of cutCalculator

Depth of cutformula for milling

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As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.

Generally, cross drilling is a simple, but limited method. It is limited because suppose the workpiece is being held horizontally in a vice. Then a piece of round material the same diameter of the rod being drilled is fitted in the chunk of the drill. The vice is then moved so that when a ruler is placed along the side of the piece of material in the chunk it then just touches the side of the material in the vice.

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Cutting speeddefinition

The cutting force during a milling operation depends on the depth of cut, chip load, raw material, cutting angles, and the total length of engagement between the cutting edges of the endmill and the material being cut. All the parameters stay constant throughout the operation except for cutting-edge engagement. The length of the helix, which is in contact with the material, varies as the cutter rotates.Therefore, a typical graph for the cutting forces acting on a solid carbide endmill as a function of time (or rotation angle) is like shown here.However, specific combinations of diameters, number of flutes, helix angles, and depth of cut yield a constant contact length independent of the rotation angle, therefore, a constant force.Since the diameter, helix angle, and flute count of the milling cutter can not be changed. We can find an optimal cut depth that will yield a constant cutting force:You can use our above calculator to find out this depth of cut. All the multiples of this depth will also yield constant force.When you machine with a constant force, you will get less vibrations, a better surface finish, and a longer too-life.You can also use this theory in another effective way. Suppose you have a mass-production job and must constantly machine at a certain depth. If you reverse the formulas, you can find specific combinations of diameter, flute count, and helix angles to yield constant force and smooth machining. The result will be non-standard figures. But it may be well worth designing and purchasing a special cutter according to these parameters for a mass-production job.You can use our above calculator to find out the optimal milling cutter geometry for your required depth of cut.Radial Depth of Cut (Cut Width)The Radial depth of cut is also called Stepover and Cut Width. It is designated by ae or RDOC.The maximum possible radial depth is the cutter’s diameter.When the radial depth is larger or equal to the cutter’s radius, the chip load is similar to the feed per tooth.The chip load is reduced for smaller cut widths because of the chip thinning effect. (See below)Chip Thinning EffectIn a milling operation, the Chip Thickness varies between the point of entry (A) and the Point of Exit (C).When the Radial Depth of Cut is greater or equal to the cutter’s radius, The maximum Chip thickness equals the Feed Per Tooth.When the radial depth of cut is smaller than the cutter’s radius (Point B), the maximum chip thickness gradually decreases even though the feed per tooth remains the same.This phenomenon is called Chip Thinning.Chip Thinning allows dramatic productivity gain since you can multiply the Feed by the Chip Thinning Factor (RCTF) while keeping the Chip Load within the recommended range! Learn more about it in our detailed guide about chip thinning\( \large RCTF = \)\( \huge \frac{1}{\sqrt{1-\left ( 1 – 2 \times \frac{Ae}{D} \right )^{2}}} \)Depth Of Cut Effects On MachiningIf we understand each effect, we can make informed decisions about changes in radial or axial depth of cut to solve the problem we have on hand. Assuming that the Cutting speed, spindle speed, cutter diameter, and feed are constant, let’s have a look at what changes in AE and AP are affecting.Productivity:The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)

You can also use this theory in another effective way. Suppose you have a mass-production job and must constantly machine at a certain depth. If you reverse the formulas, you can find specific combinations of diameter, flute count, and helix angles to yield constant force and smooth machining. The result will be non-standard figures. But it may be well worth designing and purchasing a special cutter according to these parameters for a mass-production job.You can use our above calculator to find out the optimal milling cutter geometry for your required depth of cut.Radial Depth of Cut (Cut Width)The Radial depth of cut is also called Stepover and Cut Width. It is designated by ae or RDOC.The maximum possible radial depth is the cutter’s diameter.When the radial depth is larger or equal to the cutter’s radius, the chip load is similar to the feed per tooth.The chip load is reduced for smaller cut widths because of the chip thinning effect. (See below)Chip Thinning EffectIn a milling operation, the Chip Thickness varies between the point of entry (A) and the Point of Exit (C).When the Radial Depth of Cut is greater or equal to the cutter’s radius, The maximum Chip thickness equals the Feed Per Tooth.When the radial depth of cut is smaller than the cutter’s radius (Point B), the maximum chip thickness gradually decreases even though the feed per tooth remains the same.This phenomenon is called Chip Thinning.Chip Thinning allows dramatic productivity gain since you can multiply the Feed by the Chip Thinning Factor (RCTF) while keeping the Chip Load within the recommended range! Learn more about it in our detailed guide about chip thinning\( \large RCTF = \)\( \huge \frac{1}{\sqrt{1-\left ( 1 – 2 \times \frac{Ae}{D} \right )^{2}}} \)Depth Of Cut Effects On MachiningIf we understand each effect, we can make informed decisions about changes in radial or axial depth of cut to solve the problem we have on hand. Assuming that the Cutting speed, spindle speed, cutter diameter, and feed are constant, let’s have a look at what changes in AE and AP are affecting.Productivity:The productivity of the machining process is measured by its Metal Removal Rate (MRR).\(\large MRR\,[\frac {Inch^{3}}{min}] = W\,\times\,F_n\,\times\,V_c\,\times\,12\)Use our MRR Calculator to calculate it and learn more about this important propertyWe can see from the formula two things:As we increase both AP and AE, we gain more productivity.Both depth directions have the same effect. So a process with AE=0.5″ and AP=0.75″ will yield the same output as a process with AE=0.75″ and AP=0.5″.We would increase AP and AE extensively in an ideal world to gain high productivity. Unfortunately, this is not the case in real life, as we will have many more parameters to consider.Chip Load:The chip load during a milling process depends on cutter geometry, cutting speed, table feed, and radial depth of cut. The axial depth of cut has a zero effect on the chip load. (Learn More)Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

Chip Thinning EffectIn a milling operation, the Chip Thickness varies between the point of entry (A) and the Point of Exit (C).When the Radial Depth of Cut is greater or equal to the cutter’s radius, The maximum Chip thickness equals the Feed Per Tooth.When the radial depth of cut is smaller than the cutter’s radius (Point B), the maximum chip thickness gradually decreases even though the feed per tooth remains the same.This phenomenon is called Chip Thinning.

We cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

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Basically, cross drilling is the drilling of a round hole through the middle of a round bar. This is difficult, because it takes precision to drill on a round surface. It is necessary to use the right tools in this process, otherwise the whole manufacturing may not make it to completion. The main problem with cross drilling is that if the round workpiece is placed in a vice on an x-y fitting it seems so easy to move the workpiece until the tip of the center drill appears to be at the very center of the workpiece. Then once the use of the drill bit is in play, you will not find out if the hole is off center until after the drilling is complete.

Use our Chip Load Calculator to calculate it and learn more about this important propertyWe cannot exceed a certain chip load for each geometry without damaging the cutting edge or hurting the tool-life. AP has zero effect on the chip load. but AE does according to the Chip Thinning Factor. So, we can keep the same productivity and decrease the chip load by “playing” with the proportion between AP and AE.A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will have a lower chip load depending on the chip thinning factor.Machining Power Consumption:The power consumption in a milling process is calculated by the Metal Removal Rate (MRR) times the Specific Cutting Force (KC).\(\large P[HP] = \LARGE \frac{MRR\,\times\,KC}{400}\)\(\large P[kW] = \LARGE \frac{MRR\,\times\,KC}{60,000}\)Use our Machining Power Calculator to calculate it and learn more about this important propertyWe saw above that MRR depends on AP and AE in the same proportion. However, the second parameter in the formula is the Specific Cutting Force (KC). It depends mainly on the workpiece material but also on the chip thickness and the radial depth. For the same MRR, a reduction in AE (and an increase in AP) will yield lower power consumption. For Example:A process with AE=0.5″ and AP=0.75″ will yield the same productivity as a process with AE=0.75″ and AP=0.5″, but the latter will require lower power consumption from the CNC machine.Bending Force:Both AP and AE increase the bending force when they are larger. However, the axial depth of cut is much more influential. Therefore, if you face problems related to bendings, such as chatter or non-straight walls, you should decrease the AP before you touch your AE.Heat Removal:As seen in the sketch, each cutting edge absorbs heat when it is engaged with the material and cools downs when it is in contact with air. The “air time” percentage depends on the radial depth of cut. Therefore, you can reduce the AE if you have fast wear associated with overheating. The Axial depth has no direct influence on heat removal.Related Pages:Metal Removal Rate Calculator and FormulasMilling Calculators and FormulasSpeeDoctor: Speed & Feed Calculator (Milling, Turning, Drilling & grooving)« Back to Glossary IndexRelated Glossary Terms:Radial Depth of Cut (Milling AE)Axial Depth of Cut (Milling AP)Milling Feed Rate (Table Feed)Chip LoadCutting SpeedCutting EdgeChip ThinningMetal Removal Rate (MRR)Specific Cutting Force (KC & KC1)CNC Machine

The typical (and wrong!) opinion is that the larger the depth, the more vibrations will be in the cut. However, there are optimized cut depths that create minimum vibrations.