CuttingParams - Machining Parameter Reference

Purpose: Quick lookup and calculation of cutting parameters. Starting points that work, with adjustment guidance.

When to Activate

• "What's the SFM for 316 stainless?"

• "Feeds and speeds for 7075 aluminium"

• "What RPM for a 12mm endmill in steel?"

• "Recommended DOC for titanium roughing"

• "Help me optimize my cutting parameters"

Core Formulas

Spindle Speed (RPM)

RPM = (SFM × 3.82) / Diameter (inches) RPM = (Vc × 1000) / (π × Diameter mm) RPM = (Vc × 318.3) / Diameter (mm)

Where:

• SFM = Surface Feet per Minute
• Vc = Cutting Speed in m/min

Feed Rate

Turning:

Feed (mm/min) = Feed per Rev (mm/rev) × RPM

Milling:

Feed (mm/min) = Feed per Tooth (mm/tooth) × Number of Teeth × RPM

Metal Removal Rate (MRR)

Turning:

MRR (cm³/min) = DOC × Feed × Vc × 1000

Milling:

MRR (cm³/min) = WOC × DOC × Feed Rate / 1000

Material Parameters - Turning

Aluminium Alloys

Material Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev) DOC Rough (mm)

6061-T6 300-500 400-600 0.2-0.4 0.08-0.15 2-5

7075-T6 250-400 350-500 0.15-0.35 0.08-0.12 2-4

2024-T3 250-400 350-500 0.15-0.35 0.08-0.12 2-4

Cast Aluminium 200-350 300-450 0.15-0.3 0.08-0.12 1.5-3

Tool: Uncoated carbide, polished rake face, sharp edge Coolant: Flood or mist, water-soluble OK

Carbon & Alloy Steels

Material Hardness Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev) DOC Rough (mm)

1018 130 HB 180-250 220-300 0.2-0.4 0.08-0.15 2-4

1045 180 HB 150-220 180-260 0.15-0.35 0.08-0.12 1.5-3.5

4140 200 HB 120-180 150-220 0.15-0.3 0.08-0.12 1.5-3

4140 300 HB 80-120 100-150 0.1-0.25 0.05-0.1 1-2.5

4340 280 HB 90-140 120-170 0.1-0.25 0.05-0.1 1-2.5

Tool: Coated carbide (CVD for roughing, PVD for finishing) Coolant: Flood, high-pressure preferred

Stainless Steels

Material Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev) DOC Rough (mm)

303 120-180 150-220 0.15-0.3 0.08-0.12 1.5-3

304 100-150 120-180 0.12-0.25 0.06-0.1 1-2.5

316 80-130 100-160 0.1-0.22 0.05-0.1 1-2

316L 80-120 100-150 0.1-0.2 0.05-0.1 1-2

17-4PH (H1025) 70-110 90-140 0.1-0.2 0.05-0.08 0.8-1.8

17-4PH (H900) 50-80 70-100 0.08-0.15 0.04-0.08 0.5-1.5

Tool: PVD coated carbide (TiAlN, AlTiN), positive rake Coolant: High-pressure flood essential, don't let it rub Warning: Work hardens - stay aggressive, don't dwell

Tool Steels

Material Condition Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev)

D2 Annealed 60-100 80-120 0.1-0.2 0.05-0.1

D2 Hardened (58-62 HRC) CBN/Ceramic only 80-150 0.05-0.12 0.03-0.08

H13 Annealed 80-120 100-150 0.12-0.22 0.06-0.1

H13 Hardened (48-52 HRC) 40-70 60-100 0.08-0.15 0.04-0.08

A2 Annealed 70-110 90-140 0.1-0.2 0.05-0.1

S7 Annealed 80-120 100-150 0.12-0.22 0.06-0.1

Tool: For hardened - CBN or ceramic inserts Coolant: Often dry for hardened (CBN), flood for annealed

Titanium Alloys

Material Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev) DOC Rough (mm)

CP Grade 2 60-90 80-120 0.15-0.25 0.08-0.12 1-2.5

Ti-6Al-4V 40-70 55-90 0.1-0.2 0.06-0.1 0.8-2

Ti-6Al-4V (aged) 35-55 45-75 0.08-0.15 0.05-0.08 0.5-1.5

Tool: Uncoated or PVD carbide, sharp edge, positive rake Coolant: HIGH-PRESSURE flood (70+ bar), copious amounts Warning: Fire risk with chips, poor thermal conductivity

Superalloys

Material Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev) DOC Rough (mm)

Inconel 718 25-45 35-60 0.1-0.18 0.05-0.1 0.5-1.5

Inconel 625 25-40 35-55 0.08-0.15 0.05-0.08 0.5-1.2

Hastelloy C-276 20-35 30-50 0.08-0.15 0.04-0.08 0.4-1

Waspaloy 20-40 30-55 0.08-0.15 0.05-0.08 0.5-1.2

Tool: Ceramic (roughing), CBN (finishing), or whisker-reinforced Coolant: High-pressure flood or dry with ceramic Warning: Extreme tool wear, work hardens badly

Plastics

Material Vc (m/min) Feed (mm/rev) DOC (mm) Notes

Delrin/Acetal 200-400 0.1-0.3 1-4 Sharp tools, watch heat

Nylon 150-300 0.1-0.25 1-3 Flexible, support well

PEEK 100-200 0.08-0.2 0.5-2 Expensive, careful

PTFE 150-300 0.1-0.25 1-3 Very flexible

Polycarbonate 150-300 0.1-0.2 0.5-2 Stress cracking risk

Tool: Sharp, polished, uncoated carbide or PCD Coolant: Air blast or mist (avoid flooding most plastics)

Brass & Bronze

Material Vc Rough (m/min) Vc Finish (m/min) Feed Rough (mm/rev) Feed Finish (mm/rev)

Free-cutting Brass 200-400 300-500 0.15-0.35 0.08-0.15

Naval Brass 150-250 200-350 0.12-0.28 0.06-0.12

Phosphor Bronze 100-180 150-250 0.1-0.22 0.05-0.1

Aluminium Bronze 80-140 120-200 0.1-0.2 0.05-0.1

Tool: Uncoated carbide, neutral or slightly negative rake for brass Coolant: Often dry, light mist for finish

Material Parameters - Milling

Aluminium Alloys

Material Vc (m/min) Fz Rough (mm/tooth) Fz Finish (mm/tooth) Ae Rough Ap Rough

6061-T6 300-600 0.1-0.2 0.05-0.1 50-70% 1-2×D

7075-T6 250-500 0.08-0.18 0.04-0.08 50-70% 1-1.5×D

Tool: 2-3 flute, polished, high helix (45°), uncoated or ZrN

Steels

Material Hardness Vc (m/min) Fz Rough (mm/tooth) Fz Finish (mm/tooth) Ae Rough Ap Rough

1018 130 HB 150-250 0.08-0.15 0.04-0.08 40-60% 0.5-1×D

4140 200 HB 100-180 0.06-0.12 0.03-0.06 30-50% 0.5-1×D

4140 300 HB 60-100 0.04-0.1 0.02-0.05 25-40% 0.3-0.7×D

Tool: 4+ flute, AlTiN or TiAlN coated, variable helix

Stainless Steels

Material Vc (m/min) Fz Rough (mm/tooth) Fz Finish (mm/tooth) Ae Rough Ap Rough

304 80-140 0.05-0.1 0.03-0.06 30-50% 0.3-0.8×D

316 60-120 0.04-0.09 0.02-0.05 25-45% 0.3-0.7×D

17-4PH 50-100 0.04-0.08 0.02-0.05 25-40% 0.3-0.6×D

Tool: 5+ flute, AlTiN coated, variable pitch, through-coolant Strategy: High-efficiency milling (HEM) / trochoidal preferred

Titanium

Material Vc (m/min) Fz (mm/tooth) Ae Ap Notes

Ti-6Al-4V 40-70 0.05-0.1 10-20% 1-2×D HEM essential

Tool: 5+ flute, variable helix, through-coolant, sharp Strategy: Light radial, deep axial, high-pressure coolant

Superalloys

Material Vc (m/min) Fz (mm/tooth) Ae Ap Notes

Inconel 718 20-45 0.03-0.08 10-15% 0.5-1.5×D Ceramic or CBN

Tool: Ceramic endmills for roughing, CBN for finishing Strategy: Light engagement, rigid setup essential

Drilling Parameters

Material Vc (m/min) Feed (mm/rev) Peck Depth Notes

Aluminium 80-150 0.15-0.3 3×D Through-coolant preferred

Mild Steel 25-40 0.1-0.25 1-2×D Flood coolant

Stainless 15-30 0.08-0.18 0.5-1×D High-pressure, frequent peck

Titanium 12-25 0.06-0.12 0.3-0.5×D Through-coolant essential

Inconel 8-15 0.04-0.1 0.2-0.3×D Carbide or CBN

Peck Drilling Guide

Hole Depth Peck Frequency Retract

< 3×D No peck needed

3-5×D Every 1×D Full retract

5-10×D Every 0.5×D Full retract

10×D Gundrilling

Threading Parameters

Single-Point Threading (Turning)

Material Vc (m/min) Infeed Method Passes

Aluminium 100-200 Flank/Modified 4-6

Steel 60-100 Modified flank 6-10

Stainless 40-80 Modified flank 8-12

Titanium 25-50 Radial 10-15

DOC per pass: Start at 0.2-0.3mm, reduce progressively

Thread Milling

Material Vc (m/min) Fz (mm/tooth)

Aluminium 150-300 0.05-0.1

Steel 80-150 0.03-0.08

Stainless 50-100 0.02-0.06

Titanium 30-60 0.02-0.05

Tapping

Material Vc (m/min) Notes

Aluminium 20-40 Spiral flute, flood

Steel 10-25 Spiral point, flood

Stainless 5-15 Form tap or spiral flute

Titanium 3-8 Spiral flute, high-pressure

Insert Selection Guide

Turning Insert Grades

Material Roughing Finishing

Aluminium Uncoated, polished PCD or uncoated polished

Steel (<300 HB) CVD coated PVD coated

Steel (>300 HB) Ceramic/CBN CBN

Stainless PVD (TiAlN) PVD (AlTiN)

Titanium Uncoated or PVD Uncoated sharp

Inconel Ceramic CBN or ceramic

Insert Geometry

Application Nose Radius Rake Lead Angle

Heavy roughing 1.2-1.6mm Negative 45°

Light roughing 0.8mm Neutral 90°

Finishing 0.4mm Positive 90°

Precision finish 0.2mm Positive 90°

Interrupted cut 0.8-1.2mm Negative 45°

Troubleshooting Parameters

Problem: Poor Surface Finish

Symptom Likely Cause Fix

Rough, torn Speed too low Increase Vc 20%

Feed marks visible Feed too high Reduce feed 20%

Chatter marks Vibration Reduce DOC, increase feed

Built-up edge Wrong speed/material Increase speed, change insert

Smearing Rubbing Sharper insert, increase feed

Problem: Rapid Tool Wear

Wear Type Cause Fix

Flank wear Speed too high Reduce Vc 15-20%

Crater wear Heat/chemical Better coating, reduce speed

Notch wear Work hardening Vary DOC, change lead angle

Chipping Interrupted/shock Tougher grade, reduce feed

Built-up edge Speed too low Increase Vc, better coating

Problem: Chatter/Vibration

Cause Solution

Tool overhang Reduce stickout, larger shank

Light cut Increase feed or DOC

Wrong speed Adjust RPM (try ±20%)

Part not rigid Better workholding, steadies

Insert nose radius Smaller radius

Problem: Chip Control

Issue Material Solution

Bird's nest Stainless, aluminium Chipbreaker, increase feed

Stringy chips Ductile materials Higher feed, chipbreaker

Long chips Low carbon steel Increase feed, DOC

Chip packing Deep holes Peck drilling, through-coolant

Welding to tool Aluminium, stainless Increase speed, better coating

Swiss Machine Parameters (CITIZEN)

Small Diameter Work (Ø3-10mm)

Material Vc (m/min) Feed (mm/rev) DOC (mm)

303SS 80-120 0.02-0.06 0.2-0.8

316SS 60-100 0.02-0.05 0.15-0.6

Brass 150-250 0.03-0.08 0.3-1.0

Aluminium 200-350 0.03-0.08 0.3-1.2

Ti-6Al-4V 30-50 0.01-0.04 0.1-0.4

LFV Settings (CITIZEN LFV)

Material Use LFV? Frequency Amplitude

316SS Yes 10-20 Hz 0.05-0.15mm

304SS Yes 10-20 Hz 0.05-0.15mm

Titanium Yes 8-15 Hz 0.03-0.1mm

Aluminium Rarely

Brass No

Plastics Sometimes 5-10 Hz 0.02-0.08mm

LFV Benefits: Breaks chips into small segments, eliminates bird-nesting, improves surface finish on gummy materials

Quick Reference Cards

Turning - Starting Points

ALUMINIUM: Vc=400 Feed=0.2 DOC=3mm STEEL: Vc=180 Feed=0.2 DOC=2mm STAINLESS: Vc=100 Feed=0.15 DOC=1.5mm TITANIUM: Vc=50 Feed=0.12 DOC=1mm INCONEL: Vc=30 Feed=0.1 DOC=0.8mm

Milling - Starting Points

ALUMINIUM: Vc=400 Fz=0.15 Ae=50% Ap=1×D STEEL: Vc=150 Fz=0.08 Ae=40% Ap=0.7×D STAINLESS: Vc=90 Fz=0.06 Ae=30% Ap=0.5×D TITANIUM: Vc=50 Fz=0.06 Ae=15% Ap=1.5×D (HEM) INCONEL: Vc=30 Fz=0.05 Ae=10% Ap=1×D (HEM)

RPM Quick Calc (metric)

RPM = (Vc × 318) / Diameter(mm)

Examples @ Vc=100 m/min: Ø6mm = 5,300 RPM Ø10mm = 3,180 RPM Ø12mm = 2,650 RPM Ø16mm = 1,990 RPM Ø20mm = 1,590 RPM Ø25mm = 1,270 RPM Ø50mm = 636 RPM

Integration

• CNCSetup: Auto-populate cutting parameters in setup sheets

• TribalKnowledge: Store proven parameters that beat book values

• QuoteEstimator: More accurate cycle times with real parameters

• PlantCapability: Material-specific machine recommendations