KEVOS® MAKEOS · Manufacturing
Milling Cut Planner (Speed, Thinned Feed, Power and Torque)
What spindle speed and feed should I program for this milling cut, and will the machine have the power?
Milling set-up from cutter and cut data: spindle speed from cutting speed (capped at the spindle limit), feed per tooth raised to keep the target maximum chip thickness at light radial engagement, table feed and removal rate, average chip thickness and specific cutting force (Kienzle), cutting power and torque against the machine’s power, and the feed that would use full power.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Cutter and cut | ||
| Cutter diameter | mm | Cutter diameter. |
| Number of teeth | Teeth (inserts) on the cutter. | |
| Cutting speed | m/min | Recommended cutting speed for the tool and material. |
| Target maximum chip thickness | mm | Maximum chip thickness the tool maker recommends. |
| Radial engagement | mm | Radial width of cut. |
| Axial depth of cut | mm | Axial depth of cut. |
| Lead (entering) angle | ° | Lead angle of the cutting edge (90° for square shoulder). |
| Material | ||
| Specific cutting force kc1.1 | N/mm² | Specific cutting force at 1 mm chip thickness for the material. |
| Kienzle exponent mc | Kienzle exponent for the material. | |
| Machine | ||
| Maximum spindle speed | rpm | Spindle speed limit. |
| Spindle power | kW | Rated spindle power. |
| Spindle efficiency | % | Efficiency from motor to cutter. |
Method and formulas
- n = 1000 V_c ÷ π D (capped at the spindle limit).
- Below half-diameter engagement f_z = h_ex D ÷ [2√(a_e (D − a_e))] ÷ sin κ; otherwise h_ex ÷ sin κ.
- v_f = f_z z n; MRR = a_e a_p v_f; engagement angle φ = arccos(1 − 2a_e ÷ D); h_m = 360 f_z sin κ a_e ÷ (π D φ).
- k_c = k_c1.1 h_m^(−mc); P = MRR k_c ÷ 60×10⁶ ÷ η; feed for full power ∝ (P_max ÷ P)^(1 ÷ (1 − mc)).
- Example: a 50 mm, 4-tooth cutter at 180 m/min runs at 1,145.9 rpm and 572.96 mm/min, using 3.1707 kW.
Limitations
- Average power; peak torque on few-tooth cutters is higher.
- Material constants and tool recommendations come from the tool maker.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Program a new milling cut quickly and safely
- Check whether a roughing cut fits the spindle power
- Raise feed for light radial cuts without overloading
Who it is for
- Machinists
- CNC programmers
- Manufacturing engineers
What you get
- Spindle speed, feed per tooth and table feed
- Chip thickness, removal rate and power
- Torque and full-power feed
Interpreting the result
- If spindle power limits, reduce axial depth before feed; feed per tooth controls tool life and finish.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1084–1101, 1162–1167. Topic reference; no source tables or recommended settings are reproduced.
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Open the Milling Cut Planner (Speed, Thinned Feed, Power and Torque) calculator
