KEVOS® MAKEOS · Manufacturing
Stock Removal Plan (Bar Volume, Chips, Machining Time, Power)
How much of this bar blank turns into chips, how long does it take to remove at my cutting conditions, and does the machine have the power?
Plan for machining a part from round bar: stock volume and mass from the bar diameter and cut length (as the solid volume tool), the material removed for the finished part volume and the material yield, the metal removal rate, cutting and motor power from the specific cutting force (as the turning power tool), the cutting time to remove the stock, and the stock cost, checked against the machine power and your least yield.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Bar diameter | mm | Diameter of the bar stock. |
| Cut length of the blank | mm | Length of bar cut for one part, including facing and parting allowances. |
| Finished part volume | cm³ | Volume of the finished part (from CAD). |
| Density | kg/m³ | Density of the material. |
| Bar price | $/kg | Price of the bar. |
| Cutting | ||
| Cutting speed | m/min | Cutting speed for roughing. |
| Feed | mm/rev | Feed per revolution. |
| Depth of cut | mm | Depth of cut. |
| Specific cutting force kc | N/mm² | Specific cutting force of the material. |
| Machine efficiency | % | Efficiency of the spindle drive. |
| Available spindle power | kW | Spindle power. |
| Least material yield | % | Least share of the bought material that ends up in the part. |
Method and formulas
- Stock volume = π D² ÷ 4 × L (as the solid volume tool); removed = stock − finished.
- Removal rate Q = v_c × a_p × f; cutting power = k_c a_p f v_c ÷ 60 000; motor power = cutting ÷ efficiency (as the turning power tool).
- Cutting time = volume removed ÷ Q; yield = finished ÷ stock.
- Example: 282.74 cm³ of bar, 132.74 cm³ to chips (53.052% yield); 44.248 s at 180 cm³/min and 7.5 kW.
Limitations
- Roughing time only; finishing, tool changes and handling are extra.
- Constant removal rate; small diameters may be speed-limited.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Decide whether a part is better near-net-shape
- Estimate roughing time from bar
- Check a machine’s power for heavy roughing
Who it is for
- Process planners
- Estimators
- Machinists
What you get
- Stock volume, mass and cost
- Volume removed, chip mass and yield
- Removal rate, power and cutting time
Interpreting the result
- Low yield on costly material points to forgings, castings or near-net bar sizes.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 82–88, 1084–1101. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
Open the Stock Removal Plan (Bar Volume, Chips, Machining Time, Power) calculator
