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Whereas a tool with a minimum stick-out has very less scope for deflection under the action of cutting force and can be used to deliver comparatively stronger forces.

The difference between spindle speed and cutting speed can be understood by the fact that two circles of different diameters, rotating at the same RPM, will cover different distances.

A carbide cutting tool can handle stronger force than HSS tools, and therefore can be used for machining at a faster speed and feed configuration.

However, machining a material at too high or too low spindle speed can damage the workpiece and drastically affect the tool life.

Apart from these, there are various other factors, such as workpiece material, cutting tool material, rigidity of the CNC machine, tool deflection, etc., that indirectly affect the optimal speed and feed configuration for a machining operation.

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Drilling operation on lathe is performed by using a drill bit, and therefore the optimal speeds and feeds for the process should be calculated by using the formula for drilling operations. However, lathe consists of a rotating workpiece, and the RPM involved in the calculations is the spindle speed of the chuck.

However, the speed and feed calculations for turning operations is quite similar to milling and drilling, with the only difference being the concerned diameter for calculations.

Generally, high speed with a slow feed rate is recommended for producing smooth cuts, but machining the material at an extremely high speed can result in overheating and tool damage.

It is one of the most important machining parameters. Calculating the optimal chip load for a machining process can help set the optimal feed rate of the process.

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Furthermore, lathe tools used for turning operations are mostly single-point cutting tools, hence, chip load is equal to the cutting feed per revolution (in inches per revolution).

Due to its larger size, the 1/2″ cutting tool will complete the cutting operation faster than the 1/8″ tool, irrespective of the quality of cut.

Where S denotes the spindle speed in RPM, Vs denotes cutting speed in SFM, and D denotes the diameter of the cutting tool in inches.

This article provides a detailed guide about the speeds and feeds of a machining operation and explains how to calculate optimal values.

Speeds and feeds refer to different velocities of a cutting process. While cutting speed determines surface feet of material removed per minute (SFM), spindle speed is the rotational speed of the cutting tool/workpiece (RPM), and feed rate is the speed at which the cutting tool advances along the workpiece.

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A circle with a larger diameter has a comparatively greater circumference, and therefore, each rotation of the larger circle covers a greater distance than the smaller circle.

Generally, a slow feed rate with high RPM produces clean cuts with a high surface finish, whereas a high feed rate might result in a rough cut with a comparatively poor surface finish.

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Chip load, also known as feed per tooth, can be defined as the thickness of the chips removed during a machining process.

Cutting speed, along with the feed rate and depth of cut, determines the material removal rate (MRR) during a machining process.

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Therefore, to attain a quality cut, it is important to consider the diameter of the tool when setting the optimal RPM for the process.

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Therefore, spindle speed can also be defined as the ratio of cutting speed at the tool-workpiece interface and its circumference.

Similarly, the optimal chip load of a cutting tool for a particular workpiece material can also be obtained from the tool catalog provided by the manufacturer.

Yes, the depth of cut is an important factor that affects the chip load, and therefore affects the optimal speed and feed for a machining process. Generally, as the depth of cut increases, the optimal feed rate decreases.

A tool with a long shank is more prone to being deflected under strong cutting force, and therefore cannot be used for high speeds and feeds configurations.

No. Although the calculated speeds and feeds consider all the possible variables involved in the process, there are certain variables that vary from one setup to another, such as rigidity of the machine, tool stick-out, vibrations of the machine, etc. Therefore, the calculated speeds and feeds do not always ensure perfect results, and it is necessary to perform test runs and tune the parameters according to your setup.

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Then you can perform the following calculations to obtain the optimal spindle speed and feed rate for different machining operations.

Generally, the optimal cutting speed of a tool can be determined from the reference manual provided by the manufacturer.

Speeds and feeds of a machining process are directly dependent upon various factors such as the diameter of the cutting tool, the number of flutes, and the chip load.

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As lathe machines consist of a rotating workpiece, we consider the machined diameter of the workpiece (instead of tool diameter) to calculate the optimal spindle speed.

As a result, when running at the same RPM setting, the cutting speed (SFM) of the tool with a larger diameter is greater than the tool with a smaller diameter.

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Machining operations of a CNC Lathe are different from other operations because instead of a rotating tool, lathe machines consist of a rotating workpiece.

The spindle speed primarily depends upon the ability of your CNC machine, cutting tool, and type of material being machined.

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The cutting speed of a process depends upon factors such as workpiece material, cutting tool material, and expected tool life.

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Generally, hard materials, like metals, are difficult to machine, and therefore require a slower feed rate than soft materials like wood.

Whereas soft materials like wood are relatively easy to machine and require a high RPM to glide the cutting tool through the workpiece.

Furthermore, machining hard metals require greater shearing force to perform the cutting action, therefore a slow RPM and high-torque configuration is ideal for such operations.

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It must be noted that the product of multiplying chip load with the number of flutes, gives the cutting feed in inches per revolution (IPR).

Getting started with a CNC requires thorough knowledge of various parameters, such as speeds, feeds, depth of cut, chip load, etc., that determine its functionality.

Whereas in a multi-flute cutter, the cutting operation is performed by all the flutes, and generally, the number of chips produced in one revolution is equal to the total number of flutes.

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When calculating the speeds and feeds for a machining operation, it must be noted that the optimal cutting speed (SFM) can be obtained from the reference catalog provided by the tool manufacturer.

As a result, the cutting force is equally distributed among different flutes, thereby reducing the risk of damaging the cutting tool.

A cutting tool with a single tooth will produce a single chip in one revolution, which means, the entire cutting action will be performed by one tooth.

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But what are the factors that affect these parameters and how do you identify the optimal speeds and feeds for the process?

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P (blue) is for steels, M (yellow) is for stainless steel, K (pink) for cast irons, N (green) for non-ferrous metals like aluminum, S (brown) for superalloys like titanium alloys, and H (gray) for high-temperature alloys.

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