Milling speeds and feedsChart

HVOF tungsten carbide coating is used for industries such as; steel and metal production, print and paper, railway manufacturing, automotive and glass manufacturing.

Before diving into numbers and values, you need to be aware that the following variables will heavily influence the quality of your cuts and the achievable chip load on the same machine.

Milling speeds and feedschart pdf

We have the capabilities and facility to perform a service for a complex range of parts. Whether the equipment is small individual components or large drums like rails and tanks. Our HVOF tungsten carbide coating involves the combustion of fuel gas and oxygen which reaches temperatures of 3,000˚C. The super-heated gas is ejected by an automated gun which we manually set ourselves.

These concepts can be visually summarized on a graphic, where the feedrate is plotted against the spindle rotational speed, and which helps us to identify 6 different zones.

Mar 27, 2021 — What are others using? Should I profile cut with an 1/8" bit so my feed rate is closer to what it should be based on chip load. For reference ...

If you are not yet familiar with your machine, we compiled a starter chip load table with lower values. They are intentionally low to help you get confident with the machine no matter the type of engagement, the hardness of your material, etc...

Feedrates are found using the formula given earlier in this document, but Fusion360 embeds a very handy chip load calculator which gives you the mill’s chip load for given feed and speed.

During some milling operations, more than ¼th of your tool’s circumference “touches” the material during the milling. As a result, the end mill can’t cool down properly and tends to overheat easily.

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Turningspeeds and feedscalculator

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Based on this knowledge, we can now use tables that will allow us to calculate our feeds & speeds and achieve an optimal chip load for any given material.

Feed per tooth formula

The harder the piece, the more deflect your end mill will bear. This will cause chatter and vibrations. Be patient when milling hard material and use smaller steps or lower your feedrate.

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On the other side of the graphic, if you reduce the feed rate too much relative to spindle speed, the flutes of your end mill will start rubbing the material instead of cutting nice chips. This action will make your tool overheat, and thus soften. Its sharp edges will become dull and if you keep cutting with dull edges and you will start to see a very deteriorated surface finish on your material.

Cutting speed formula PDF

Similarly, we suggest you slowly increase the depth of your cuts while doing these tests. Indeed, excessive depth of cut will result in tool deflection (see this article to understand why that can be problematic).

Working closely with our customers over the years, we have developed our products and services to deliver the best value, most effective thermal spray coatings solution, first time, every time and with a stress-free service that suits everyone.

HVOF tungsten carbide coating is used for a variety of applications and industries In conditions and environments which encounter extreme wear – the thermal spray coating is extremely effective.

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An important factor to consider while reading these tables is the tool diameter. A larger end mill will indeed be able to handle a larger chip load.

The parameter that links these concepts and that is widely used as a standard metric to determine optimal feeds & speeds is called chip load.

Cutting Speed calculatorMilling

In this Alphatek article, we have discussed what is HVOF tungsten carbide coating, the benefits it gives machinery and parts, and which company provides this service.

This is a great starting point if you are a novice. When you are feeling more confident, slowly increase the chip load towards the “Advanced chip load table” values.

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HVOF tungsten carbide coatings are perfect for protecting products and parts that are susceptible to wear and corrosion. Here are the benefits of applying Tungsten Carbide:

Hence, getting your feeds & speeds right simply means finding the sweet spot where your tool is spinning at the perfect speed relative to its moving speed inside the material. That sweet spot can mean different things depending on your goal: achieving the best surface finish, machining your parts the fastest, or maximizing your tool life.

Now let's imagine that your spindle can't run faster than 10 000rpm. We can still increase the feed rate by using a 3-flutes end mill and keep a constant chip load:

Cutting speed formula for turning

A general rule of thumb is to take passes that are around half the diameter of your mill. But remember, as mentioned above: some more complex or hard materials requires lower depth of cut (typical examples are aluminium and  plexiglas...).

Understanding how feeds and speeds work is critical if you want to improve your CNC skills. It will help you to optimize your machining speeds, to obtain a better surface finish and most importantly to have a longer tool life. Here's an overvie of what this article goes through:

High-Velocity Oxygen Fuel (HVOF) tungsten carbide coating is a thermal spray process in which fuel and oxygen are mixed, fed into a combustion chamber, and ignited. The gas produced in the combustion chamber has an extremely high temperature and pressure and is ejected through a nozzle at supersonic speeds.

Let’s define an arbitrary feedrate of 2 000 mm/min. Using the former equation, we find that the spindle has to rotate at 10 000 rpm to achieve the proper chip load:

Based on this mathematical relation, we observe that if we want to increase the feed rate to cut that plywood faster, we will have to increase the spindle rotational speed as well to keep a constant chip load :

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Chip load, also called “feed per tooth”, is the thickness of material that is fed into each cutting edge as it moves through the work material.

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Depending on how deep you want your end mill to go inside the material, you will have to adapt your feed rate to spare it.

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HVOF tungsten carbide coating is a commonly used coating material used in a variety of industries for numerous amounts of products.

If you're using end mills that you bought at Mekanika, you can access the pre-parametered feeds and speeds for Fusion360 here on the product pages.

An end mill is a cutting tool and with time, it will eventually get dull. As it gets worn out, you will need to take it easier and reduce the feedrate to keep a good surface finish. You can also just replace it or resharpen it.

As stated earlier in the article, we recommend that you start by setting the actual feedrate of your machine below the value from the table and gradually increase it. In general, you will find that your optimal feeds & speeds will be determined from experience or trial-and-error. For instance, for most materials, you can typically set the spindle speed between 15000-25000rpm and adjust your feed rate to obtain nice results with your machine.

Because of the coatings proven ability to save costs across the entire production process whilst being highly effective, it is a widely popular product.

As illustrated above, there are mainly two bad spots that you want to avoid. The first one happens when you reduce your spindle speed too much relative to the feed rate. Doing so, you’re forcing the flutes of your end mill to cut off too much material, which can lead to unwanted vibration or worse, a broken tool.

Feed rate formula for turning

Let's illustrate this concept and imagine you want to cut plywood with a 6mm 2-flutes end mill. In our case, the recommended chip load for plywood is around 0,1mm/tooth (cf. the Advanced chip load table at the end of this article).

Tungsten carbide is typically found as a fine grey powder. When combined with a small portion of metallic powder it can be turned into carbide coatings known for strong resistance to abrasion, erosion, and wear.

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We have an unparalleled experience. Here at Alphatek, we have a combined 100+ years of cumulative coating expertise in house.

20221123 — Any manufacturing process has a certain amount of variation. Tolerances account for this variation by defining the margins within which a part ...

So again, for these heavier milling operations, you will need to use a lower feedrate to allow your mill to stay cool, or simply reduce the depth of cut.

At Alphatek, HVOF tungsten carbide thermal spray coating is one of, if not, our most frequent thermal sprays that are applied for wear-resistant surface treatments.

Always clamp your workpiece in the best possible way. A loose workpiece will vibrate while being cut and cause a bad surface finish. If you are not sure about your clamping, use wood screws to attach your workpiece in many points to the spoiler board. It is not the fanciest clamp in the world, but it is fast and efficient.