Speeds and Feeds

PLTW Engineering

Computer Integrated Manufacturing

Activity 2.3.2 Speeds and Feeds

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 Lesson Goals
Identify common cutting tools
Learn the definition of speeds and feeds
Calculate cutting speeds and feed rate

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 Basic Cutting Tools

Non-Center
Ball End
Center Cutting End
Mill
Cutting End Mill
Mill Indexable
Shell Mill

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 Basic Cutting Tools

Combination
Drill & Countersink

Spotting Drill

Countersink

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 Flutes

2 Flute End Mill 4 Flute End Mill

More room for chip More cutting edges,
evacuation longer tool life
Used for light metals Used for harder metals
Weak, short tool life Clogs easily in deep
cuts

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 Center Vs. Non-Center Cutting

2 Flute 4 Flute 4 Flute

Non-Center
Center Center
Cutting
Cutting Cutting

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 Milling Tools
Tool Description Application

¼” 2 Flute Facing, profiling,

HSS Single pocketing,
End Mills for slotting,
cutting roughing, and
aluminum – finishing
3/8 shank x 1
¼ cutting
length
¼” 2 Flute Surfacing,
Ball End Mill slotting,
for aluminum profiling,
– 3/8 shank x roughing, and
1 ¾ cutting finishing
7
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 Milling Tools
Tool Description Application

¼” Engraving, de-
Countersink & burring,
De-burring countersink,
tool – 90 spot drilling
Degree
#3 Combined Spot drilling,
drill & engraving
countersink
90 degree

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 Milling Tools
Tool Description Application

¼” Spotting Spot drilling,

drill 90 deg engraving

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 Cutting Tool Material Video
Play the Cutting Tool Material and Cutting Tool
Geometry video

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 Definitions
Cutting Speed: The rate of a tool measured in
surface feet per minute
Spindle Speed: The number of revolutions per
minute (rpm) that is made by the cutting tool of a
machine
Feed Rate: The distance advanced by the cutting
tool along the length of the work for every
revolution of the spindle

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 Spindle Speed
Spindle Speed: The number of revolutions
per minute (rpm) that is made by the
cutting tool of a machine
Spindle speed is expressed as revolutions
per minute (rpm)
Spindle speed is calculated by dividing the
cutting speed by the circumference of the
tool

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 Spindle Speed Formula

Circumference

𝑁=
(
𝐶𝑆 12
𝑖𝑛
𝑓𝑡 )
𝜋𝑑

N = Spindle speed (rpm)

CS = Cutting speed (surface ft / min)
d = Diameter (inches)
d = Circumference (inches/rev)

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Mil
lin
g
Sp
Recommended Cutting Speeds
ee
Milling Speeds for High-Speed Steel Tools
ds
for Material Cutting Speed in surface ft/min
Hi
gh Magnesium 300
Sp Aluminum 250
ee
d Brass and Bronze 150
St
eel Copper 100
To Cast Iron (Soft) 80
ol
s Cast Iron (Hard) 50
M C Mild Steel 90
a u
Cast Steel 80
t t
e t Alloy Steel (Hard) 40
r i
i n Tool Steel 50
a g Stainless Steel 60
l
S Titanium 50
p
High Manganese Steel 30
e
e Note: Double Speed for Carbide Cutting Tools
d

i
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n
 Spindle Speed Calculation Example
What spindle speed should be used to mill
aluminum with a ½ inch end mill?
N = Spindle speed (rpm)

𝑁=
𝐶𝑆 12 (
𝑖𝑛
)
𝑓𝑡 CS = Cutting speed (surface ft / min)
𝜋𝑑 d = Diameter (inches)
d = Circumference (inches/rev)

𝑁=
250
𝑠𝑓
𝑚𝑖𝑛
12(𝑖𝑛
𝑓𝑡 ) Milling Speeds for High-Speed Steel Tools
Material Cutting Speed in surface ft/min
1
( 3.14 ( 0.5 0 𝑖𝑛𝑐h ) ) Aluminum 250
𝑟𝑒𝑣
𝑟𝑒𝑣
𝑁 =1910.83
𝑚𝑖𝑛
𝑟𝑒𝑣
𝑁 =1900
𝑚𝑖𝑛
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 Your Turn to Calculate Spindle
Speed
Try to calculate the spindle speed before
revealing the solution on the next slide.
What spindle speed should be used to mill brass
with a ¼ inch end mill?

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 Your Turn Solution
What spindle speed should be used to mill brass
with a ¼ inch end mill?

𝑁=
𝐶𝑆 12( 𝑖𝑛
𝑓𝑡 )
𝜋𝑑

𝑁=
150
𝑠𝑓
𝑚𝑖𝑛 (
12
𝑖𝑛
𝑓𝑡) Milling Speeds for High-Speed Steel Tools
Material Cutting Speed in surface ft/min
1
( 𝜋 ( 0.2 5 𝑖𝑛𝑐h ) ) Brass and Bronze 150
𝑟𝑒𝑣
𝑟𝑒𝑣
𝑁 =2292.99
𝑚𝑖𝑛
𝑟𝑒𝑣
𝑁 =2200
𝑚𝑖𝑛

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 Feed Rate
Feed Rate: The distance advanced by the cutting
tool along the length of the work for every
revolution of the spindle.

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 Feed Rate Formula

𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

fm = Feed rate (inches/min)

ft = Feed per tooth (or chip load) (inch/tooth•rev)
nt = Number of teeth on the cutting tool (unitless)

N = Spindle speed (rpm) 𝑁 =

(
𝐶𝑆 12
𝑖𝑛
𝑓𝑡 )
𝜋𝑑

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 Recommended Tool Feed per Tooth

Tool Feed per Tooth (inch/tooth•rev)

Material Face Mill Side Mill End Mill
Magnesium .0050-.0200 .0040-.0100 .0050-.0100
Aluminum .0050-.0200 .0040-.0100 .0050-.0100
Brass and Bronze .0040-.0200 .0040-.0100 .0050-.0100
Copper .0040-.0100 .0040-.0070 .0040-.0080
Cast Iron (Soft) .0040-.0160 .0040-.0090 .0040-.0080
Cast Iron (Hard) .0040-.0100 .0020-.0060 .0020-.0060
Mild Steel .0040-.0100 .0020-.0070 .0020-.0100
Alloy Steel (Hard) .0040-.0100 .0020-.0070 .0020-.0060
Tool Steel .0040-.0080 .0020-.0060 .0020-.0060
Stainless Steel .0040-.0080 .0020-.0060 .0020-.0060
Titanium .0040-.0080 .0020-.0060 .0020-.0060
High Manganese Steel .0040-.0080 .0020-.0060 .0020-.0060
Note: Double the recommended speed for carbide cutting tools

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 Feed Rate Calculation Example
Calculate the feed rate for end milling aluminum
with a 2 flute, ½ inch HSS end mill.
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁
Tool Feed per Tooth (inch/tooth•rev)
Material Face Mill Side Mill End Mill
Aluminum .0050-.0200 .0040-.0100 .0050-.0100

0.0050
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

𝑛𝑡 =2 (unitless)
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 Feed Rate Calculation Example
Calculate the feed rate for end milling aluminum
with a 2 flute, ½ inch HSS end mill.
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

𝑁=
𝐶𝑆 12( 𝑖𝑛
𝑓𝑡 ) Milling Speeds for High-Speed Steel Tools
Material Cutting Speed in surface ft/min
𝜋𝑑 Aluminum 250

𝑁=
250
𝑠𝑓
𝑚𝑖𝑛
12
𝑖𝑛
𝑓𝑡 ( )
1
( 3.14 ( 0.5 0 𝑖𝑛𝑐h ) )
𝑟𝑒𝑣
𝑟𝑒𝑣 Do not round here because you need
𝑁 =1910.83
𝑚𝑖𝑛 this value in the feed rate calculation

22 Copyright 2021. Project Lead The Way, Inc.

 Feed Rate Calculation Example
Calculate the feed rate for end milling aluminum
with a 2 flute, ½ inch HSS end mill.
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑖𝑛𝑐h 𝑟𝑒𝑣
𝑓 𝑚 =0.005 0 × 2× 1910 .83
𝑡𝑜𝑜𝑡h ×𝑟𝑒𝑣 𝑚𝑖𝑛

𝑖𝑛𝑐h𝑒𝑠
𝑓 𝑚 =19
𝑚𝑖𝑛

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 Your Turn to Calculate Feed Rate
Try to calculate the feed rate before revealing the
solution on the next slide.
Calculate the feed rate for face milling aluminum
with a 4 flute, ½ inch HSS end mill.

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 Your Turn Solution
Calculate the feed rate for face milling aluminum
with a 4 flute, ½ inch HSS end mill.
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

Tool Feed per Tooth (inch/tooth•rev)

Material Face Mill Side Mill End Mill
Aluminum .0050-.0200 .0040-.0100 .0050-.0100

0.0050
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

𝑛𝑡 = 4 (unitless)

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 Your Turn Solution
Calculate the feed rate for face milling aluminum
with a 4 flute, ½ inch HSS end mill.
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁

𝑁=
𝐶𝑆 12( 𝑖𝑛
𝑓𝑡 ) Milling Speeds for High-Speed Steel Tools
Material Cutting Speed in surface ft/min
𝜋𝑑 Aluminum 250

𝑁=
250
𝑠𝑓
𝑚𝑖𝑛
12
𝑖𝑛
𝑓𝑡 ( )
1
( 3.14 ( 0.5 0 𝑖𝑛𝑐h ) )
𝑟𝑒𝑣
𝑟𝑒𝑣 Do not round here because you need
𝑁 =1910.83
𝑚𝑖𝑛 this value in the feed rate calculation

26 Copyright 2021. Project Lead The Way, Inc.

 Your Turn Solution
Calculate the feed rate for face milling aluminum
with a 4 flute, ½ inch HSS end mill.
𝑓 𝑚 = 𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑖𝑛𝑐h 𝑟𝑒𝑣
𝑓 𝑚 =0.005 0 × 4 ×1910 .83
𝑡𝑜𝑜𝑡h ×𝑟𝑒𝑣 𝑚𝑖𝑛

𝑖𝑛𝑐h𝑒𝑠
𝑓 𝑚 =38
𝑚𝑖𝑛

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 Factors That Affect Feed Rates
Power of spindle motor
Condition of cutting tool
Depth of cut
Quality of surface finish required
Roughing vs. finish cuts
Condition of the machine
Strength of fixture

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 Plunge Feed Rate
Feed rate at which mill can plunge into
material while still cutting material
The plunge feed rate is calculated as one
half of the feed rate

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 Plunge Feed Rate Formula
𝑓𝑚
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2

N = Spindle speed (rpm)

CS = Cutting speed (surface ft / min)
d = Diameter (inches)
d = Circumference (inches/rev)

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 Plunge Rate Calculation Example
Calculate the plunge feed rate for plunging into
mild steel with a 4 flute, ½ inch HSS end mill.
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
Tool Feed per Tooth (inch/tooth•rev)
Material Face Mill Side Mill End Mill
Mild Steel .0040-.0100 .0020-.0070 .0020-.0100

𝑓 𝑡 ×𝑛𝑡 × 𝑁 0.0020
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑛𝑡 = 4 (unitless)
31 Copyright 2021. Project Lead The Way, Inc.
 Plunge Rate Calculation Example
Calculate the plunge feed rate for plunging into
mild steel with a 4 flute, ½ inch HSS end mill.
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2

𝑁=
𝐶𝑆 12( 𝑖𝑛
𝑓𝑡 ) Milling Speeds for High-Speed Steel Tools
Material Cutting Speed in surface ft/min
𝜋𝑑 Mild Steel 90

𝑁=
90
𝑠𝑓
𝑚𝑖𝑛
12 (
𝑖𝑛
𝑓𝑡 )
1
( 3.14 ( 0.5 0 𝑖𝑛𝑐h ) )
𝑟𝑒𝑣
𝑟𝑒𝑣 Do not round here because you need
𝑁 =687.90
𝑚𝑖𝑛 this value in the feed rate calculation

32 Copyright 2021. Project Lead The Way, Inc.

 Plunge Rate Calculation Example
Calculate the plunge feed rate for plunging into
mild steel with a 4 flute, ½ inch HSS end mill.
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑖𝑛𝑐h 𝑟𝑒𝑣
0.002 0 × 4 ×687.90
𝑡𝑜𝑜𝑡h × 𝑟𝑒𝑣 𝑚𝑖𝑛
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2

𝑖𝑛𝑐h𝑒𝑠
𝑓 𝑚 =2.75 Round down to be conservative
𝑚𝑖𝑛
𝑖𝑛𝑐h𝑒𝑠
𝑓 𝑚 =2.7
𝑚𝑖𝑛

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 Your Turn to Calculate Plunge Rate
Try to calculate the feed rate before revealing the
solution on the next slide.
Calculate the plunge feed rate for plunging
copper with a 4 flute, ¼ inch HSS end mill.

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 Your Turn Solution
Calculate the plunge feed rate for plunging
copper with a 4 flute, ¼ inch HSS end mill.
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
Tool Feed per Tooth (inch/tooth•rev)
Material Face Mill Side Mill End Mill
Copper .0040-.0100 .0040-.0070 .0040-.0080

𝑓 𝑡 ×𝑛𝑡 × 𝑁 0.0040
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑛𝑡 = 4 (unitless)
35 Copyright 2021. Project Lead The Way, Inc.
 Your Turn Solution
Calculate the plunge feed rate for plunging
copper with a 4 flute, ¼ inch HSS end mill.
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2

𝑁=
𝐶𝑆 12( 𝑖𝑛
𝑓𝑡 ) Milling Speeds for High-Speed Steel Tools
Material Cutting Speed in surface ft/min
𝜋𝑑 Copper 100

𝑁=
100
𝑠𝑓
𝑚𝑖𝑛
12
𝑖𝑛
𝑓𝑡 ( )
1
( 3.14 ( 0.2 5 𝑖𝑛𝑐h ) )
𝑟𝑒𝑣
𝑟𝑒𝑣 Do not round here because you need
𝑁 =1528.66
𝑚𝑖𝑛 this value in the feed rate calculation

36 Copyright 2021. Project Lead The Way, Inc.

 Your Turn Solution
Calculate the plunge feed rate for plunging
copper with a 4 flute, ¼ inch HSS end mill.
𝑓 𝑡 ×𝑛𝑡 × 𝑁
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2
𝑖𝑛𝑐h 𝑟𝑒𝑣
0.00 4 0 × 4 ×1528.66
𝑡𝑜𝑜𝑡h × 𝑟𝑒𝑣 𝑚𝑖𝑛
𝑓 𝑚 (𝑝𝑙𝑢𝑛𝑔𝑒) =
2

𝑖𝑛𝑐h𝑒𝑠
𝑓 𝑚 =12.23 Round down to be conservative
𝑚𝑖𝑛
𝑖𝑛𝑐h𝑒𝑠
𝑓 𝑚 =12
𝑚𝑖𝑛

37 Copyright 2021. Project Lead The Way, Inc.

 Special Operations
These special operations require slower speeds.
Reaming: ½ to ⅔ of the speed used for drilling
material.
Counterboring: ¼ of the speed used for drilling
material.
Countersinking: ¼ of the speed used for drilling
material.
Tapping (threading): Determined by many factors.
Typical range from 50 to 300 rpm.

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 Engineering Formula Sheet

The number of revolutions per

minute (rpm) that is made by the
cutting tool of a machine
The distance advanced by the
cutting tool along the length of
the work for every revolution of
the spindle
The rate of a tool measured in
surface feet per minute
Feed per tooth (or chip load)

39 Copyright 2021. Project Lead The Way, Inc.

 References
Black, J., Kohser R. (2008). DeGarmo’s
materials and
processes in manufacturing (10th ed.).
Danvers, MA: John Wiley & Sons, Inc.
Kibbe, R.R., Neely, J.E., Meyer, R.O., & White,
W.T. (2002). Machine tool practices. Upper
Saddle River, NJ: Prentice Hall.
Oberg, E., Jones F. D., Horton, H. L., & Ryffell, H.
H. (2000). Machinery’s handbook (26th ed.).
New York, NY: Industrial Press Inc.

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