User Guide

Milling Cutters
 BROOKE TECHNICAL SERVICES

This handbook is intended to help you get maximum performance

from BROOKE cutting tools.

FULL SPECIFICATIONS IN BROOKE CATALOGUES

Brooke Cutting TOOLS Ltd is a world class manufacturer producing

precision cutting tools to international standards and specifications
which include British Standard, DIN, ISO, ANSI and JIS. Full details
of specifications are listed in our catalogues which are available from
leading Industrial Distributors or directly from Brooke .

PRODUCT RANGE
STANDARDS & SPECIALS

The BROOKE range consists of nearly 13 000 standard items and

we have a cutting tool available for almost every application.

2 Brooke
Cutting Tools Limited
 CONTENTS
Page
SELECTION OF STEELS 5

SURFACE TREATMENTS 6-7

END MILLS
- End Mill Nomenclature 8
- End Mill Applications 10 - 11
- Hints for Successful - End Mill Usage 12
- Tolerances 9

SHANK CUTTERS
- Shank Cutter Nomenclature 13
- Shank Cutter Applications 16 - 17
- Tolerances 14 - 15

ARBOR MOUNTED CUTTERS 18

SIDE AND FACE CUTTERS 18

CYLINDRICAL CUTTERS 20 / 23
- Arbor Mounted Cutter Nomenclature 18 - 19
- Arbor Mounted Cutter Applications 22 / 24
- Hints for Successful Arbor Mounted 28 / 29
Cutter Usage

SLITTING SAWS
- Slitting Saw Applications 26
- Hints for Successful Slitting Saw Usage 27
- Tolerances 25

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Cutting Tools Limited
3
 CONTENTS (cont.)
Page
TECHNICAL INFORMATION
- Technical Data Chart 30 / 33
- Feed per Tooth Chart 34 / 41
- Peripheral Speed to rpm Conversion Chart 42 - 43
- Speed & Feed Formulae 44
- Climb vs Conventional Milling 45 - 46
- General Tolerances 49
- Problem Solving 47
- Difficult to Machine Materials 50
- Re-Sharpening Hints 51
- Useful Formulae, Conversion Charts etc. 52 / 60

IF YOU CANNOT FIND AN ANSWER TO YOUR PROBLEM IN

THIS BOOKLET PLEASE CONTACT THE BROOKE.

4 Brooke
Cutting Tools Limited
 CUTTING TOOL MATERIALS
Brooke cutting tools are manufactured from the finest steel available.
The heat treatment process is controlled by our Metallurgical
laboratory using advanced computerised and electronic
instrumentation. High Speed Steel contains various elements such
as Molybdenum, Tungsten, Cobalt and Vanadium and must be
specially heat treated to produce the ideal combination of strength,
toughness and wear resistance.
BROOKE products are manufactured from one of the following High
Speed Steels depending on the product and application.

C Cr W Mo V Co Hardness (HRC)
M2 0.9 4 6 5 2 - 63 - 65
M35 0.9 4 6 5 2 5 64 - 66
M42 1.1 4 1.5 9.5 1 8 66 - 68.5(70)
M9V 1.25 4.2 3.5 8.5 3.0 - 64 - 66

M2 is the standard High Speed Steel and is used where toughness

is important, together with a good standard of wear resistance and
red hardness.

M35 is a development of M2 and contains 5% cobalt which gives

improved hardness, wear resistance and red hardness. It may be
used when cutting higher strength materials.

M42 can be heat treated to very high hardness levels of up to 70

HRC (1 000 HV) although normally a slightly lower figure will be
employed to retain toughness. This steel is ideal for machining higher
strength materials and work hardening alloys such as stainless steels,
nimonic alloys etc. Despite its high hardness, M42 has good
grindability characteristics due to lower vanadium content.

M9V material is mainly used in the manufacture of machine taps

because of its good wear resistance, good grinding capabilities, high
hardness and excellent toughness.

Cutting tools may shatter

eye protection should be worn

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Cutting Tools Limited
5
 SURFACE TREATMENTS
Bright Finish
A bright finish tool has no surface treatment and is suitable for general
purpose use.

Blue Finish
A blue finish is achieved by steam tempering - a thermal process
which imparts a non-metallic surface to the tool. This surface is
porous and by absorbing lubricant, helps prevent rusting, reduces
friction and cold welding, resulting in increased tool life.
Steam tempered products can successfully be used at slightly
increased machining rates or on more difficult to machine materials.

Gold Oxide
This is a metallic brown coloured surface treatment achieved by a
low temperature temper and is normally only used on cobalt products
for identification purposes.

Nitriding
Nitriding imparts a hard surface to the tool and is used for prolonging
tool life and machining difficult to machine materials. Because
nitriding makes the edge more brittle, care must be exercised in the
type of application.
Nitrided tools are normally also steam tempered.

Titanium Nitride Coating (TiN)

TiN coating is a very hard, gold coloured surface coating a few
microns thick which is applied by means of a complex process, called
Physical Vapour Deposition (PVD), by advanced modern equipment.
The coating is non-metallic and therefore reduces cold welding.
In certain applications increased speed and feed rates can be
achieved because of:

(a) The hardness of the coating.

(b) The reduction in cutting force required due to a decrease in
friction between the tool and the workpiece.
Tool performance will deteriorate after re-sharpening.

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Cutting Tools Limited
TiCN (Titanium Carbonitride)
The addition of carbon to TiN results in a significant increase in the
hardness of TiCN over TiN. TiCN also has a much lower coefficient
of friction which enhances the surface finish of components machined
with TiCN coated tools, higher productivity can be achieved on a
wide range of materials but, in particular stainless steel, titanium
and nickel based alloys.

TiALN (Titanium Aluminium Nitride)

In addition to a higher hardness than both TiN and TiCN the aluminium
in the coating imparts a much greater oxidation stability. This is as a
result of a very thin film of (Aluminium Oxide) being formed on the
surface of the TiALN. The film is self repairing, leading to additional
increased service life. These improvements allow the coating to
withstand much higher temperatures which in turn allows increased
cutting conditions, especially useful when machining Cast Iron and
tough steels.

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Cutting Tools Limited
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 END MILLS

END MILL NOMENCLATURE

OVERALL LENGTH

CUTTING LENGTH

CUTTING SHANK
DIAMETER DIAMETER

HELIX
END
ANGLE
TEETH

Shank Options

Plain Shank
Tolerance h7 on metric
shank diameter (see page
49 for tolerance tables)

THREAD
LENGTH

Threaded Shank

Tolerance h8 on metric /
Fractional shank diameter

THREAD
20 T.P.I.
WHITWORTH
FORM
Flatted Shank

Tolerance h6 on metric
shank diameter (see page
49 for tolerance tables

8 Brooke
Cutting Tools Limited
Typical End Mill Options

Two Flute End Mill

Tolerance e8 on cutting
diameter (see page 49 for
tolerance tables)

Ball Nose End Mill

Tolerance e8 on cutting
diameter (see page 49 for
tolerance tables)

Three Flute End Mill

Tolerance e8 on cutting
diameter (see page 49 for
tolerance tables)

Multi-Flute End Mill

Tolerance js14 on cutting

diameter (see page 49 for
tolerance tables)

Roughing End Mill

Tolerance js 16 on cutting
diameter (see page 49 for
tolerance tables)

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Cutting Tools Limited
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END MILL APPLICATIONS

Two and Three Flute End Mills

Two and three flute end mills are shank type cutters with peripheral
teeth and end teeth of the plunging type. Intended for general purpose
use, they have right hand cutting, right hand helical teeth; they are
used on keyway and closed slotting operations where the close minus
tolerance of the cutting diameter allows slot widths to be produced in
one pass. These cutters are also extensively used when profiling
and end milling aluminium alloys, due to the greater chip space
required by this material.

Ball Nose Two Flute End Mills

Ball nosed two flute end mills are manufactured to the same
tolerances as the normal two flute end mill, and have a centre cutting
ball end. They are used extensively in die making for cutting fillets,
radiused slots, pocketing etc. These cutters have right hand cutting,
right hand helical teeth.

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Cutting Tools Limited
Multi-Flute End Mills

Multi-flute end mills are shank type cutters with peripheral teeth and
end teeth of the both plunging and non-plunging type. Designed for
general purpose use they have right hand cutting, right hand helical
teeth, and are used in stepping and profiling applications. They can
also be used on slots where the plus tolerance of the cutting diameter
is not critical.

Roughing End Mills

Shank type cutters with right hand cutting, right hand helical teeth
on the periphery with roughing profile and with heavy duty end teeth.
These cutters are robust and durable even under heavy cutting
conditions on a wide range of materials. They are intended for rapid
and heavy rates of stock removal where surface finish is of lesser
importance. Available in coarse and fine pitch knuckle form and flat
crest type.

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Cutting Tools Limited
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HINTS FOR SUCCESSFUL END MILL USAGE

It is assumed that the workpiece clamping and machine size and

power are adequate for the intended operation.

Always select the most suitable tool for the job on hand; a few minutes
spent on selection can save hours of machining. Use roughing end
mills when removing large amounts of stock; two or three flute end
mills for deep slotting applications, for edge cutting and espically
when machining light alloys. Use multi-flute end mills for edge cutting
as well as for light finishing cuts.

Use threaded shank or flatted shank cutters where heavy stock

removal and high tooth loads are involved. Plain shank cutters are
particularly suitable for quick change CNC applications and for pre-
setting off the machine.

Where possible check workpiece condition and hardness.

Check chucks and collects regularly ensuring that they are in good
condition. Always clean cutter shanks and collets prior to assembly.
Check that cutters are running true.

The most likely cause of cutter run-out is damaged chucks and

collets.

Maintain cutters in a sharp condition to ensure maximum stock

removal, surface finish and maximum power requirement.

Re-sharpen immediately when signs of wear are visible, since

regrinding is then a relatively quick operation requiring little stock
removal and with resulting increase in tool life. (See page 51 for
resharpening details). Cutter storage is of paramount importance
due to the brittle nature of the hardened cutting edges of all cutting
tools. Poor storage often causes damage such as chipping of the
cutting edges and breakage of corners, resulting in a tool which is
useless. As in all machining operations cleaniless is essential.

The best machining results are produced by cutters operating at the

correct speed and feed to suit the material being worked. (See page
30 for technical data.)
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Cutting Tools Limited
 SHANK CUTTERS

SHANK CUTTER NOMENCLATURE

SHANK
DIAMETER

THREAD 20 T.P.I.
THREAD
LENGTH

WHITWORTH
RIGHT HAND
SHANK LENGTH

RECESS
DIAMETER
OVERALL LENGTH

RECESS LENGTH
CUTTING
WIDTH

SIDE
TEETH

HELIX
ANGLE

CUTTER DIAMETER

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Cutting Tools Limited
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Types of shank cutters

Dovetail Cutter

Tolerance js16 on cutting diameter

(see page 49 for tolerance tables)

Inverted Dovetail Cutter

Tolerance js16 on cutting diameter

(see page 49 for tolerance tables)

Corner Rounding Cutter

Tolerance H11 on radius and js14 on cutting tip

(see page 49 for tolerance tables)

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Cutting Tools Limited
T-Slot Cutter

Tolerance d11 on metric cutting diameter and width

Tolerance h12 on fractional cutting diameter and width
(see page 49 for tolerance tables)

Woodruff Cutter

Tolerance h11 on metric cutting diameter and e8 on width

(see page 49 for tolerance tables)

Tolerance on fractional diameter is

size +0,381
+0,127
and on width is
size +0,000
- 0,025

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Cutting Tools Limited
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SHANK CUTTER APPLICATIONS

Dovetail Cutters

These angle cutters have right hand cutting straight teeth and non-
plunging end teeth. They are used wherever dovetails or angles are
required and are available in a range of angles and diameters.

Corner Rounding Cutters

Straight tooth cutters with right hand cutting teeth. Intended to produce
a true convex up to 90° of arc.

16 Brooke
Cutting Tools Limited
T-Slot Cutters

Shank type cutters with right hand cutting alternate helical peripheral
teeth as well as teeth on either face. Intended for opening out existing
slots to form the T-slots used extensively on machine tables. They
are produced in a range of diameters and widths to allow clearance
on a standard range of bolt head sizes.

Woodruff Cutters

Shank type cutters with right hand cutting alternate helical peripheral
teeth. Available in a range of diameters and widths. Designed to
produce slots to suit standard woodruff keys.

HINTS FOR SHANK CUTTER USAGE

(See page 12 for hints on end mill usage)

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Cutting Tools Limited
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 ARBOR MOUNTED CUTTERS

SIDE AND FACE CUTTER

NOMENCLATURE

Side and Face Cutter- (Staggered Tooth shown)

RAKE
ANGLE WIDTH

KEYWAY
LAND

SIDE TEETH

HELIX
BORE ANGLE
DIAMETER

PERIPHERAL PERIPHERAL
CLEARANCE TEETH
SIDE TEETH
CONCAVITY

Tolerance js16 on metric cutting diameter and k11 on width

(see page 49 for tolerance tables)

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Cutting Tools Limited
Shell End Mills

Plain Form

RAKE
OVERALL
ANGLE
LENGTH

HELIX
ANGLE
DIAMETER

INTERNAL
DIAMETER

See page 24 for application.

Roughing Form

See page 24 for application.

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Cutting Tools Limited
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Side and Face Cutter- Straight Tooth

Tolerance js16 on metric/fractional cutting diameter and k11 on metric/

fractional width
(see page 49 for tolerance tables)

Cylindrical Cutter

Tolerance js16 on cutting diameter and width

(see page 49 for tolerance tables)

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Cutting Tools Limited
Single Angle Cutter

Tolerance js16 on cutting diameter and js14 on width

(see page 49 for tolerance tables)

Double Angle Cutter

Tolerance js16 on cutting diameter and width

(see page 49 for tolerance tables)

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Cutting Tools Limited
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ARBOR MOUNTED CUTTER APPLICATIONS

Staggered Tooth Side and Face Cutters

As the name suggests, side and face cutters have teeth on the
periphery as well as on the sides, Designed with rugged alternate
helical teeth, these cutters offer optimum performance when used
for deep slotting with rapid stock removal; the cutting action of the
alternate helical teeth combined with the coarse pitched side teeth
giving excellent qualities of smooth cutting, efficient stock removal
and good surface finish.

Straight Tooth Side and Face Cutters

Intended for light cuts and shallow slotting operations, the straight
tooth side and face cutter is often used in a straddle milling function
where two parallel surfaces are machined simultaneously. It is
considered to be a compromise tool due to the reduced cutting action
of its straight teeth, which cause greater shock when meeting the
workpiece than cutters with helical teeth.

22 Brooke
Cutting Tools Limited
Cylindrical Cutters

Intended for medium/light surfacing cuts these helical cutters offer

the benefits of shock reduction combined with a good cutting action.

Angle Cutters

Produced with light duty straight teeth these cutters are used mainly
for cutting dovetails, serrations and angled slots on less difficult
materials.

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Cutting Tools Limited
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Shell End Mills

With helical peripheral teeth these cutters fillthe gap between normal
shank cutters and the much larger facing cutters,this cuttter is better
suited to light/medium cuts in a facing or stepping operation with its
plain bore.

Shell End Mill (Roughing)

As the name implies, these cutters with their helical teeth and
roughing profile are particularly efficient in areas where large volumes
of stock must be removed at high speed and where tough materials
are to be worked.

24 Brooke
Cutting Tools Limited
 SLITTING SAWS

Slitting Saw - Plain

Tolerance js16 on cutting diameter and js10 on width

(see page 49 for tolerance tables)

Slitting Saw - Side Chip Clearance

Tolernace js16 on cutting diameter and js10 on width

(see page 49 for tolerance tables)

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Cutting Tools Limited
25
SLITTING SAW APPLICATIONS

Slitting Saw - Plain

Intended for shallow cutting-off operations, these saws have straight

teeth on the periphery and are tapered on width towards the bore to
prevent binding. They are available in either coarse or fine pitch to
suit the type and section of materials to be cut.

Slitting Saws - Side Chip Clearance

Intended for optimum production of deep narrow slots and for sawing
operations, these saws have alternate helical teeth on the periphery
combined with side teeth to ensure efficient stock removal, clean
cutting action, and good surface finish.

26 Brooke
Cutting Tools Limited
HINTS FOR SUCCESSFUL SLITTING SAW USAGE

± 2 times depth
of cut

It is recommended that side plates be used with slitting saws.

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Cutting Tools Limited
27
HINTS FOR SUCCESSFUL ARBOR MOUNTED CUTTER USAGE

Some of the many factors governing efficient use of bore cutters

are:-

1) Condition of machine
2) Machine power available
3) Machine capacity
4) Nature of the workpiece

Attention should be given to these factors prior to commencement.

When using arbor mounted cutters the following points should be
observed:-

Taper drive of arbor should be in good condition and fit correctly into
machine drive.

Arbor and bushes should be kept in good and clean condition; dirty
bushes cause run-out of cutters.

Arbors should be oiled and carefully stored when not in use; bent
arbors are useless and expensive to replace.

Cutters should run true to prevent overloading of one or two teeth

and extensive regrinding later.

Fit the cutter as closely as possible to the machine column with a

support as near to the cutter as the workpiece will allow.

Running bushes and support bearings should be kept clean and in

good running condition, particularly with regard to the bush faces.
Lack of support will cause damage to the cutter and the workpiece.
Always use correct lubricants.

Workpiece clamping should be rigid and able to withstand the forces

acting upon it under the action of the cutter.

Select correct speeds and feeds for the cutter in use and the nature
of the workpiece material and the size of the cut to be taken.

28 Brooke
Cutting Tools Limited
Use recommended coolants and direct flow to the point of cutting.
Consult the coolant suppliers for specific recommendations.
Adequate cooling is essential to prevent overheating of the cutter
and failures associated with overheating.

Always use drive keys between the cutter and the arbor; friction
between the cutter and the arbor bushes is seldom sufficient when
cutters are under correct load.

Never force a cutter onto a arbor or over an ill-fitted key. Protect your
hands by wrapping the cutter in a soft material when fitting or removing
it from the arbor.

Due to the brittle nature of hardened tool steels it is not advisable to

“remove” a cutter with a mallet once it has been tightened onto the
arbor.

Maintain cutters in sharp condition. Regrind as soon as wear

becomes apparent.

Store cutters carefully when not in use, using a light film of oil to
prevent rusting.

Cleanliness of cutters and arbors is essential.

Use helically fluted cutters wherever possible to minimise shock as

teeth contact the workpiece.

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Cutting Tools Limited
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 TECHNICAL INFORMATION

CUTTER TECHNICAL DATA

TENSILE
MATERIAL HARDNESS
GRADE STRENGTH
TYPE HB
N / mm²

FREE CUTTING 150 510

0.3 to 0.4% Carbon 170 580
CARBON
0.3 to 0.4% Carbon 248 830
STEEL
0.4 to 0.7% Carbon 206 675
0.4 to 0.7% Carbon 286 970

248 833
ALLOY
330 1137
STEEL
381 1265

Martensitic: Free Cutting 248 833

Std. Grade 248 833
STAINLESS
STEEL
Austenitic: Free Cutting
As Supplied
Std. Grade

NIMONIC Wrought 300 1030

ALLOYS Cast 350 1200
Titanium Comm: Pure 170 510
Titanium Comm: Pure 200 660
Titanium Comm: Pure 275 940
TITANIUM
Titanium Alloyed 340 1170
Titanium Alloyed 350 1200
Titanium Alloyed 380 1265
HSS Standard Grades 225 735
HSS Cobalt Grades 250 830
TOOL STEEL
Hot Working Steel 250 830
Cold Working Steel 250 830
CAST Grey, Malleable 240 800
IRONS Hardened 330 1137

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Cutting Tools Limited
 PERIPHERAL SPEED RANGE † CUTTING ANGLES
Refer to explanatory notes on page 32, 33

TYPE TYPE TYPE TYPE PRIMARY SECONDARY RADIAL

*A *B *C *D CLEARANCE CLEARANCE RAKE

30-40 28-40 24-32 30-40

24-32 24-32 20-26 24-32 Add 10°
18-25 18-25 14-20 18-25 8° - 20° to 9° - 14°
primary
24-32 24-32 20-26 24-32
16-25 16-20 12-20 16-25

16-20 16-20 12-16 16-20

Add 10°
12-18 12-18 10-15 10-16 8° - 20° to 9° - 14°
primary
9-15 8-14 8-12 8-12

10-20 12-16 8-15 10-20

5-10 5-10 4-8 5-10 Add 10°
8° - 20° to 9° - 14°
10-20 12-16 8-15 10-20 primary
5-10 5-10 4-8 5-10

Add 10° to
4-8 5-10 3-7 4-8 8° - 20° 9° - 14°
primary

Add 10°
7-12 5-12 5-10 7-12 8° - 20° to 9° - 14°
primary

10-20 10-20 8-15 10-20

10-16 10-20 8-13 10-16 Add 10°
8° - 20° to 9° - 14°
10-16 10-16 8-13 10-16 primary
10-16 10-16 8-13 10-16
16-20 16-20 12-16 20-28 Add 10° to
8° - 20° 9° - 14°
12-16 10-14 10-12 16-22 primary

cont on page 32

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Cutting Tools Limited
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CUTTER TECHNICAL DATA (cont)

TENSILE
MATERIAL HARDNESS
GRADE STRENGTH
TYPE HB
N / mm²

Wrought 55
ALUMINIUM Wrought 110
ALLOYS
Cast 100
Brass : Free Cutting
Low Leaded
Bronze: Silicon
COPPER As Supplied
Manganese
ALLOYS
Aluminium
Phospor
Copper

PLASTICS As Supplied

Explanatory Notes

*Cutter types

TYPE CUTTER RANGE

End mills (2, 3 & Multi-Flute)

T - Slot Cutters
A Dovetail & Inverted Dovetail Cutters
Woodruff Cutters
Corner Rounding Cutters

Side and Face Cutters

B Single and Double Angle Cutters
Slitting Saws

C Shell End Mills - Plain Tooth

32 Brooke
Cutting Tools Limited
 PERIPHERAL SPEED RANGE † CUTTING ANGLES
Refer to explanatory notes on page 32, 33

TYPE TYPE TYPE TYPE PRIMARY SECONDARY RADIAL

*A *B *C *D CLEARANCE CLEARANCE RAKE

200-1500 120-180 50-180 Add 10°

100-250 100-180 50-100 10° - 20° to 20° - 28°
40-100 50-70 30-80 primary
40-70 35-45 30-60
Add 10°
50-80 45-70 40-65 8° - 20° to 9° - 14°
40-70 35-45 30-60 primary
25-45 20-40 20-35
15-25 15-25 12-20 Add 10° to
8° - 20° 9° - 14°
15-25 15-25 12-20 primary
40-70 35-45 30-60 10° - 20° Add 10° 20° - 28°
Add 10°
50-200 50-200 10° - 20° to 9° - 14°
primary

*Cutter types (cont)

TYPE CUTTER RANGE

D Shell End Mills - Roughing

Note: For Roughing End Mills

see page 11.

† Cutting Angles
Use higher angles for smaller diameters, reducing
proportionately for larger diameters.

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Cutting Tools Limited
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END MILLS: Feeds Per Tooth Sz (mm)

Sz X 1.25 Sz X 0.78

aa = d

aa = d
aa

aa
ar = 0.1 X d ar = 0.25 X d

Table Shows Sz Values

End Carbon Alloy Stainless Nimonic
Titanium
Mill Steels Steels Steels Alloys
3 0.010 0.010 0.010 0.008 0.010
4 0.015 0.015 0.015 0.012 0.015
5 0.018 0.018 0.018 0.014 0.018
6 0.022 0.022 0.022 0.018 0.022
8 0.030 0.030 0.030 0.024 0.030
10 0.036 0.036 0.036 0.029 0.036
12 0.044 0.044 0.044 0.036 0.044
14 0.051 0.051 0.051 0.040 0.051
16 0.058 0.058 0.058 0.046 0.058
18 0.065 0.065 0.065 0.052 0.065
20 0.073 0.073 0.073 0.058 0.073
22 0.080 0.080 0.080 0.064 0.080
25 0.090 0.090 0.090 0.072 0.090
28 0.102 0.102 0.102 0.081 0.102
30 0.110 0.110 0.110 0.088 0.110
32 0.116 0.116 0.116 0.092 0.116
35 0.130 0.130 0.130 0.104 0.130
40 0.130 0.130 0.130 0.104 0.130
50 0.130 0.130 0.130 0.104 0.130
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Cutting Tools Limited
 Sz Sz

aa = 0.5 X d

aa = 0.5 X d
aa

aa
ar = d ar = d

Table Shows Sz Values

Tool Cast Manganese Aluminium Copper
Steels Irons Steels Alloys Alloys
0.009 0.010 0.008 0.013 0.013
0.013 0.016 0.012 0.019 0.019
0.016 0.022 0.014 0.023 0.023
0.020 0.028 0.018 0.028 0.028
0.027 0.036 0.024 0.039 0.039
0.032 0.040 0.029 0.046 0.046
0.040 0.045 0.036 0.057 0.057
0.046 0.056 0.040 0.066 0.066
0.052 0.064 0.046 0.075 0.075
0.058 0.070 0.052 0.085 0.085
0.065 0.080 0.058 0.092 0.092
0.072 0.088 0.064 0.104 0.104
0.080 0.095 0.072 1.117 0.117
0.091 0.110 0.081 0.132 0.132
0.100 0.120 0.088 0.143 0.143
0.104 0.127 0.092 0.150 0.150
0.117 0.142 0.104 0.170 0.170
0.117 0.142 0.104 0.170 0.170
0.117 0.142 0.104 0.170 0.170
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Cutting Tools Limited
35
 ROUGHING END MILLS:
Peripheral Speed (m/min)
Feed Per Tooth Sz (mm)

Sz Sz X 1.5 Sz X 1.8

1.5 d

1.5 d
d

d 0.3 d 0.5 d

Table Shows Sz Values

End Material Group
Mill
Size 1 2 3 4
6 0.008 0.008 0.009 0.010
8 0.013 0.013 0.015 0.015
10 0.017 0.020 0.020 0.021
12 0.023 0.025 0.025 0.033
14 0.026 0.030 0.030 0.037
16 0.030 0.038 0.038 0.044
22 0.032 0.040 0.040 0.048
25 0.035 0.042 0.042 0.050
28 0.035 0.045 0.042 0.050
30 0.040 0.045 0.045 0.056
32 0.042 0.050 0.050 0.064
35 0.013 0.013 0.015 0.015
38 0.045 0.057 0.057 0.070
40 0.045 0.057 0.057 0.070
45 0.047 0.059 0.060 0.075
50 0.060 0.074 0.075 0.090
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Cutting Tools Limited
 Peripheral Speeds
Material Cutter Speed
Material Types
Group (m/min)
1 Steels up to 500N/mm² 28 - 40
Malleble Cast Iron up to 120 HB
2 Steels of 500 - 800 N/mm² 24 - 32
Non - Alloyed Tool Steels
Pure Titanium
3 Steels of 800 - 1200 N/mm² 18 - 25
Hot Working Steels
Cast Iron of 120 - 180 HB
4 Stainless Steels 12- 18
Titanium Alloys (Annealed)
Cast Iron of more than 180 HB
5 Titanium Alloys (Hardened) 7 - 12
6 Brass and Bronze (Cast) 35 - 45
7 Brass and Bronze (Rolled) 45 - 70
8 Plastics and similar 200 - 250

Table Shows Sz Values

Material Group
5 6 7 8
0.013 0.008 0.006 0.006
0.020 0.012 0.009 0.009
0.030 0.017 0.013 0.012
0.037 0.024 0.016 0.013
0.047 0.026 0.021 0.015
0.053 0.033 0.024 0.019
0.060 0.038 0.025 0.022
0.063 0.040 0.028 0.025
0.065 0.040 0.028 0.025
0.068 0.040 0.030 0.028
0.080 0.044 0.036 0.035
0.020 0.012 0.009 0.009
0.086 0.048 0.040 0.035
0.090 0.048 0.040 0.038
0.094 0.048 0.042 0.040
0.119 0.060 0.052 0.047
Brooke
Cutting Tools Limited
37
 SIDE AND FACE CUTTERS - Staggered Tooth:
Feed Per Tooth (mm)

0.1 d

Table Shows Sz Values

Cutter Cutter Material Group

Diameter Width 1 2 3
over to
63 3 10 0.050 0.051 0.051
10 18 0.052 0.054 0.054
80 4 12 0.063 0.063 0.070
12 20 0.064 0.064 0.070
100 5 14 0.069 0.069 0.070
14 25 0.070 0.069 0.070
125 7 16 0.077 0.078 0.080
16 28 0.078 0.078 0.080
160 7 18 0.088 0.090 0.100
18 32 0.090 0.090 0.190
200 8 18 0.093 0.093 0.194
18 32 0.101 0.101 0.102
250 8 18 0.107 0.107 0.110
18 32 0.105 0.105 0.106

38 Brooke
Cutting Tools Limited
 0.1 d

Table Shows Sz Values

Material Group
4 5 6 7 8

0.050 0.051 0.050 0.046 0.020

0.052 0.053 0.052 0.048 0.020
0.063 0.063 0.063 0.056 0.020
0.063 0.063 0.063 0.056 0.020
0.070 0.070 0.070 0.062 0.020
0.070 0.070 0.070 0.070 0.020
0.078 0.080 0.080 0.080 0.020
0.078 0.080 0.080 0.080 0.020
0.090 0.090 0.090 0.090 0.020
0.090 0.090 0.090 0.090 0.020
0.093 0.094 0.093 0.093 0.020
0.102 0.102 0.101 0.101 0.020
0.108 0.110 0.108 0.108 0.020
0.104 0.105 0.104 0.104 0.020

Brooke
Cutting Tools Limited
39
 SHELL END MILLS:
Feed Per Tooth (mm)

Plain Tooth

0.1 d
0.75 d

Table Shows Sz Values

Cutter Material Group

Type
Diameter 1 2 3
40 0.080 0.080 0.080
P 50 0.080 0.080 0.080
L 63 0.100 0.100 0.100
A 80 0.100 0.100 0.100
I 100 0.100 0.100 0.100
N 125 0.100 0.100 0.100
160 0.105 0.105 0.105

R
40 0.060 0.060 0.060
O
50 0.070 0.070 0.070
U
63 0.075 0.080 0.070
G
80 0.100 0.100 0.100
H
100 0.110 0.110 0.110
I
125 0.115 0.115 0.115
N
160 0.120 0.120 0.125
G

40 Brooke
Cutting Tools Limited
 Roughing Form

0.15 d - 0.25 d
0.75 d

Table Shows Sz Values

Material Group
4 5 6 7 8
0.080 0.080 0.080 0.080 0.022
0.080 0.080 0.080 0.080 0.022
0.100 0.100 0.100 0.100 0.022
0.100 0.100 0.100 0.100 0.022
0.100 0.100 0.100 0.100 0.022
0.100 0.100 0.100 0.100 0.022
0.105 0.105 0.105 0.105 0.022

0.060 0.060 0.060 0.060 0.022

0.075 0.075 0.075 0.075 0.028
0.080 0.080 0.080 0.080 0.031
0.100 0.100 0.100 0.100 0.039
0.110 0.110 0.110 0.110 0.039
0.115 0.115 0.115 0.115 0.042
0.120 0.120 0.120 0.120 0.044

Brooke
Cutting Tools Limited
41
 PERIPHERAL SPEED
METRES
5 10 20 30 40
PER MIN
Dia.
mm Revolutions
1.0 1591 3182 6364 9546 12728
2.0 795 1590 3182 4770 6360
3.0 530 1060 2120 3180 4240
4.0 398 795 1590 2385 3180
5.0 318 636 1272 1908 2544
6.0 265 530 1060 1590 2120
7.0 227 455 910 1365 1820
8.0 199 398 796 1194 1592
9.0 177 353 706 1059 1412
10.0 159 318 636 954 1272
11.0 145 289 578 867 1156
12.0 133 265 530 795 1060
13.0 122 245 490 735 980
14.0 114 227 454 681 908
15.0 106 212 424 636 848
16.0 100 199 398 597 796
18.0 89 177 354 531 708
20.0 80 159 318 477 636
22.0 73 145 290 435 580
24.0 67 133 266 399 532
26.0 61 122 344 366 488
28.0 57 144 228 342 456
30.0 53 106 212 318 424
35.0 45 91 182 273 364
40.0 40 80 160 240 320
45.0 35 70 140 210 280
50.0 32 64 128 192 256
63.0 25 50 100 150 200
75.0 21 42 84 126 168
100.0 16 32 64 96 128

42 Brooke
Cutting Tools Limited
TO rpm CONVERSION CHART

50 60 70 80 90 100

per Minute
15910 19092 22274 25456 28638 31820
7950 9540 11130 12720 14310 15900
5300 6360 7420 8480 9540 10600
3975 4770 5565 6360 7155 7950
3180 3816 4452 5088 5724 6360
2650 3180 3710 4240 4770 5300
2275 2730 3185 3640 4095 4550
1990 2388 2786 3184 3582 3980
1765 2118 2471 2824 3177 3530
1590 1908 2226 2544 2862 3180
1445 1734 2023 2312 2601 2890
1325 1590 1855 2120 2385 2650
1225 1470 1715 1960 2205 2450
1135 1362 1589 1816 2043 2270
1060 1272 1484 1696 1908 2120
995 1194 1393 1592 1791 1990
885 1062 1239 1416 1593 1770
795 954 1113 1272 1431 1590
725 870 1015 1160 1305 1450
665 798 931 1064 1197 1330
610 732 854 976 1098 1220
570 684 798 912 1026 1140
530 636 742 848 954 1060
455 546 637 728 819 910
400 480 560 640 720 800
350 420 490 560 630 700
320 384 448 512 576 640
250 300 350 400 450 500
210 252 294 336 378 420
160 192 224 256 288 320

Brooke
Cutting Tools Limited
43
Speed and Feed Formulae

D. . rpm
v =
1000

S¹
Sz =
rpm.Z

V. 1000
rpm =
.D

S¹
Sn = rpm

S¹ = Sz. Z. rpm

a. b. S¹
V = 1000

p = 3.1416

v = speed (m/min)
D = cutter diameter (mm)
rpm = revolutions/min
Sn = feed/revolution (mm)
S¹ = feed/minute (mm)
Sz = feed/tooth (mm)
Z = number of teeth on cutter
V = chip volume (cm³ /min)
a = depth of cut (mm)
b = length of cut (mm)
44 Brooke
Cutting Tools Limited
CLIMB OR CONVENTIONAL MILLING

From the very beginning of the milling process, it was found practi-
cal to always rotate the end mill in the opposite direction to the feed
of the workpiece. This is termed conventional milling.

In conventional milling the end mill engages the workpiece at the

bottom of the cut. The end mill teeth slide along until sufficient pres-
sure builds up to break through the surface of the work. This sliding
action under pressure tends to abrade the periphery of the end mill
with resulting dulling. Also in horizontal conventional milling, the cut-
ting action has a tendency to lift the workpiece, fixture and table from
their bearings. In recent years, milling machines have been greatly
improved through backlash elimination and greater rigidity so that
climb milling is now possible. Climb milling improves surface finish
and increases tool life.

Force

Conventional Milling

Feed

Climb Milling

Feed

Force

Brooke
Cutting Tools Limited
45
In climb milling the end mill rotates in the direction of the feed. The
tooth meets the work at the top of the cut at the thickest portion of
the chip. This provides instant engagement of the end mill with the
workpiece producing a chip of definite thickness at the start of the
cut without the rubbing action resulting from conventional milling. It
further permits the gradual disengagement of the teeth and work so
that feed marks are largely eliminated.

Climb milling will often provide better product finish, permit greater
feed per tooth and prolong the cutter life per sharpening. It is par-
ticularly desirable to climb mill such materials as heat treated alloy
steels and non-free machining grades of stainless steel for better
tool life and to reduce work hardening. It is not recommended on
material having a hard scale, such as cast or scaly forged surfaces,
because abrasion would quickly ruin the cutting edges. Also some
very soft steels do not lend themselves to climb milling because of
their tendency to drag and tear.

Climb milling cannot be applied to every milling operation and should

not be attempted if the material and the machine setup are not adapted
to this type of milling.

46 Brooke
Cutting Tools Limited
PROBLEM SOLVING

Milling problems are often caused by one or more of the following

factors, which should be carefully checked in a systematic and logi-
cal manner.

Speeds and Feeds

See page 30 for recommendations.

Coolants
Seek advice from your supplier.

Cutter Selection
Always select the correct type and quality of cutter to suit the appli-
cation.

Arbors
Straightness/runout/size/wear/damage
Bushing-wear/damage.

Re-sharpening
Clearance angles. See page 51
Runout
Burning/overheating
Surface finish

Milling Machines
Slides and gib strips
Lead screws and nuts
Backlash elimination
Attachments
Defective workheads
Worn tailstocks
Worn centres

Brooke
Cutting Tools Limited
47
Workholding
Workdolder condition
Workholder suitability
Workholder alignment
Workholder rigidity

Workpiece Condition
Machine suitability
Material specifications
Material hardness
Material surface conditions
Machining characteristics

Cutter Holders
Collets
Chucks
Draw bars
Runout
Damage

48 Brooke
Cutting Tools Limited
TOLERANCES

Tolerances in µ m = 1 micron (1/1000mm)

DIAMETER OR WIDTH
3 to 6 to 10 to 18 to 30 to 50 to 80 to
Tol. 3mm
6mm 10mm 18mm 30mm 50mm 80mm 120mm
-20 -30 -40 -50 -65 -80 -100 -120
d11
-80 -105 -130 -160 -195 -240 -290 -340
-14 -20 -25 -32 -40 -50 -60 -72
e8
-28 -38 -47 -59 -73 -89 -106 -126
0 0 0 0 0 0 0 0
h6
-6 -8 -9 -11 -13 -16 -19 -22

h8 0 0 0 0 0 0 0 0
-14 -18 -22 -27 -33 -39 -46 -54
0 0 0 0 0 0 0 0
h11
-60 -75 -90 -110 -130 -160 -190 -220
0 0 0 0 0 0 0 0
h12
-100 -120 -150 -180 -210 -250 -300 -350
+20 +24 +29 +35 +42 +50 +60 +70
js10
-20 -24 -29 -35 -42 -50 -60 -70
+125 +150 +180 +215 +260 +310 +370 +435
js14
-125 -150 -180 -215 -260 -310 -370 -435
+300 +375 +450 +550 +650 +800 +950 +1100
js16
-300 -375 -450 -550 -650 -800 -950 -1100
+60 +75 +90 +110 +130 +160 +190 +220
k11
-0 -0 -0 -0 -0 -0 -0 -0
+10 +12 +15 +18 +21 +25 +30 +35
H7
0 0 0 0 0 0 0 0
+60 +75 +90 +110 +130 +160 +190 +220
H11
0 0 0 0 0 0 0 0

Brooke
Cutting Tools Limited
49
DIFFICULT TO MACHINE MATERIALS

There are number of materials which are generally regarded as being

difficult to machine. In general terms the material being worked is
considered to be difficult when it does not respond readily to normal
machining techniques. Among these “difficult’ materials are
aluminium alloys, stainless steel and work hardening steels.

Aluminium Alloys require relatively high speeds and feeds. They

respond best to cutters with few teeth and correspondingly wide chip
spaces, and can be worked very effectively by using two flute end
mills, which have the advantage of fewer teeth engaged in the cut. In
many cases coolant may not be needed to cool the cutter although it
is of benefit in lubricating and particularly in removing chips. Climb
milling gives definite advantages and shows significant benefits where
a good quality surface finish is needed. These materials can be
worked quite effectively with regular tooling, although benefits would
be obtained from custom tools in the event of large volume
production being the norm.

Stainless Steels require lower speeds and higher feed rates and
often benefits are obtained from using corner radii and chamfers.
These materials respond well to the conventional cutting method but
rigidity of machine and setup are critical. Light finishing cuts are to
avoided but where necessary should be taken at a feed rate as high
as possible to meet with surface finishing requirements. It is crucial
that these materials be “worked”, and “rubbing” of the cutter against
the workpiece should be avoided. Selection of speed and feed rates
is of great importance. Coolant must be used in large volume and be
directed at the cutting area. Benefits are often obtained from a higer
coolant concentration or from using cutting oils.

Work Hardening Steels such as some stainless and manganese

steels can be successfully machined by using the same techniques
as described for stainless steels above.

50 Brooke
Cutting Tools Limited
RESHARPENING AND CARE OF MILLING CUTTERS

The productivity of a milling machine depends to a large degree on

the efficiency of the milling cutter. Best results in both production
and cutter life are obtained by sharpening cutters correctly and care-
fully, and by taking proper care in handling and storage. A correctly
sharpened cutter requires less driving power, produces better quality
work and gives longer service than an incorrectly or hastily
sharpened cutter.

The following factors should be considered:-

Correct handling and storage to prevent damage.

Restoration of the cutting edges to their original geometry using

correct procedures.

Suitable wheel selection to ensure correct surface finish and stock

removal. Consult wheel suppliers for specific recommendations.

Remember that milling cutters are precision tools and must be

handled carefully. Damage due to incorrect handling or storage can
be seen as a flaw upon the milled surface of a workpiece. Grinding
should be needed only as a result of dulling due to use. Regrinding
to remove damage caused by rough handling must be considered to
be a wasted process which reduces the life of a cutter.

Correct clearance angles and radial rakes can be obtained from data
given on page 30, 31 & 33.

Radial
Rake Primary

Secondary

Brooke
Cutting Tools Limited
51
 GENERAL INFORMATION

INCH-MILLIMETER CONVERSION TABLE

0" 1" 2" 3"
mm mm mm mm

0 . . . . . 25.400 50.800 76.200

1/64 . . . . 0.397 25.797 51.197 76.597
1/32 . . . . 0.794 26.194 51.594 76.994
3/64 . . . . 1.191 26.591 51.991 77.391
1/16 . . . . 1.588 26.988 52.388 77.788
5/64 . . . . 1.984 27.384 52.784 78.184
3/32 . . . . 2.381 27.781 53.181 78.581
7/64 . . . . 2.778 28.178 53.578 78.978
1/8 . . . . . 3.175 28.575 53.975 79.375
9/64 . . . . 3.572 28.972 54.372 79.772
5/32 . . . . 3.969 29.369 54.769 80.169
11/64 . . . . 4.366 29.766 56.166 80.566
3/16 . . . . 4.762 30.162 55.562 80.962
13/64 . . . . 5.159 30.599 55.959 81.359
7/32 . . . . 5.556 30.956 56.356 81.756
15/64 . . . . 5.953 31.353 56.753 82.153
1/4 . . . . . 6.350 31.750 57.150 82.550
17/64 . . . . 6.747 32.147 57.547 82.947
9/32 . . . . 7.144 32.544 57.944 83.344
19/64 . . . . 7.541 32.941 58.341 83.741
5/16 . . . . 7.938 33.338 58.738 84.138
21/64 . . . . 8.334 33.734 59.134 84.534
11/32 . . . . 8.731 34.131 59.531 84.931
23/64 . . . . 9.128 34.528 59.928 85.328
3/8 . . . . . 9.525 34.925 60.325 85.725
25/64 . . . . 9.922 35.322 60.722 86.122
13/32 . . . . 10.319 35.719 61.119 86.519
27/64 . . . . 10.716 36.116 61.516 86.916
7/16 . . . . 11.112 36.512 61.912 87.312
29/64 . . . . 11.509 36.909 62.309 87.709
15/32 . . . . 11.906 37.306 62.706 88.106
31/64 . . . . 12.303 37.703 63.103 88.503

52 Brooke
Cutting Tools Limited
INCH-MILLIMETER CONVERSION TABLE (cont)
0" 1" 2" 3"
mm mm mm mm

1/2 . . . . . 12.700 38.100 63.500 89.900

33/64 . . . . 13.097 38.497 63.897 89.297
17/32 . . . . 13.494 38.894 64.294 89.694
35/64 . . . . 13.891 39.291 64.691 90.091
9/16 . . . . 14.288 39.688 65.088 90.488
37/64 . . . . 14.684 40.084 65.484 90.884
19/32 . . . . 15.081 40.481 65.881 91.281
39/64 . . . . 15.748 40.878 66.278 91.678
5/8 . . . . . 15.875 41.275 66.675 92.075
41/64 . . . . 16.271 41.671 67.071 92.471
21/32 . . . . 16.668 42.068 67.468 92.868
43/64 . . . . 17.066 42.466 67.866 92.266
11/16 . . . . 17.462 42.862 68.262 93.662
45/64 . . . . 17.859 43.859 68.859 94.859
23/32 . . . . 18.256 43.656 69.056 94.456
47/64 . . . . 18.653 44.053 69.453 94.853
3/4 . . . . . 19.050 44.450 69.850 95.250
49/64 . . . . 19.447 44.847 70.247 95.647
25/32 . . . . 19.844 45.244 70.644 96.044
51/64 . . . . 20.241 45.641 71.041 96.441
13/16 . . . . 20.638 46.038 71.438 96.838
53/64 . . . . 21.034 46.434 71.834 97.234
27/32 . . . . 21.431 46.831 72.231 97.631
55/64 . . . . 21.828 47.228 72.628 98.028
7/8 . . . . . 22.225 47.625 73.025 98.425
57/64 . . . . 22.622 48.022 73.422 98.282
29/32 . . . . 23.019 48.019 73.019 99.019
59/64 . . . . 23.416 48.816 74.216 99.616
15/16 . . . . 23.812 49.212 74.612 100.012
61/64 . . . . 24.209 49.609 75.009 100.409
31/32 . . . . 24.606 50.006 75.406 100.806
63/64 . . . . 25.003 50.403 75.803 101.203

Brooke
Cutting Tools Limited
53
 APPROXIMATE HARDNESS AND TENSILE
STRENGTH CONVERSIONS
TENSILE STRENGTH
HRB HRC HV HB Tons MPa or
inch² N/mm²
50 — 95 90 21 320
55 — 100 100 23 350
60 — 110 105 25 390
65 — 120 110 27 420
70 — 130 120 29 450
75 — 140 130 31 480
80 — 150 140 34 520
85 — 165 160 37 570
90 — 185 175 40 620
95 — 205 195 45 690
100 20 230 220 50 770
— 22 240 230 53 820
— 24 255 240 56 860
— 26 265 250 59 910
— 28 280 265 62 960
— 30 295 280 65 1000
— 32 310 290 68 1050
— 34 325 310 72 1110
— 36 345 325 75 1150
— 38 360 345 78 1200
— 40 380 365 83 1280
— 42 405 385 88 1360
— 44 425 405 92 1420
— 46 450 430 96 1480
— 48 480 455 102 1540
— 50 505 480 108 1670
— 52 545 — 112 1720
— 54 580 — 117 1800
— 56 615 — 122 1890
— 58 655 — 130 2000
— 60 695 — 135 2100
— 64 790 — 150 2320
— 66 855 — 163 2510
— 68 940 — 179 2770
— 70 1075 — 197 3030
— 75 1480 — — —
— 80 1865 — — —

HRB = Hardness Rockwell B

HRC = Hardness Rockwell C
HV = Hardness Vickers. Also DPN, VPN, DPH, VPH
HB = Hardness Brinell. Also BHN
Note:
These values should be treated as approximate only and are suitable
for calculating speeds and feeds or for general information purposes.
Do not use for treated high speed steel.
54 Brooke
Cutting Tools Limited
 HARDNESS CONVERSION CHART FOR
HIGH SPEED STEEL
HV30 HRC HV30 HRC
736 59-3/4 856 64-1/2
741 60 862 63-3/4
746 60-1/4 869 65
752 60-1/4 876 65-1/4
757 60-1/2 883 65-1/2
763 61 890 66
769 61 897 66
775 61-1/4 905 66-1/2
780 61-1/2 912 67
786 61-3/4 919 67
792 62 927 67-1/4
798 62-1/4 934 67-1/2
804 62-1/2 942 68
810 62-3/4 950 68
817 63 958 68-1/2
823 63-1/4 966 68-1/2
829 63-1/2 974 69
836 63-3/4 982 69-1/2
842 64 990 69-1/2
849 64-1/4 999 70

Typical hardness

M2 823-876 HV30 - 63-65 HRC

M35 849-920 HV30 - 64-66 HRC
M42 897-966 HV30 - 66 - 68-1/2 HRC

Depending on the nature of the tool these hardnesses may be varied,

particularly in the case of special tools where different hardnesses
may be specified.

Note:
Undue reliance should not be placed on a general conversion chart
unless it has been tested for a particular material. The above chart
applies specifically to High Speed Steel.

Brooke
Cutting Tools Limited
55
 USEFUL FORMULAE
Trigonometry
Formulae for the solution of Formulae for the solution of
RIGHT ANGLED OBLIQUE ANGLED
TRIANGLES TRIANGLES

A
A
b
c c b

C B C
B a a

opposite c The Sine rule:

Tan = =
adjacent a a b c
= =
Sin A Sin B Sin C
opposite c
Sin = hypotenuse = b The Cosine rule:
a² = b² + c² - 2bc Cos A
adjacent a b² = a² + c² - 2ac Cos B
Cos = hypotenuse =
b c² = a² + b² - 2ab Cos C

USEFUL VALUES IN TRIGNOMETRICAL RATIOS

For right angled triangles

60°
2 1 45°
1 2

30° 45°
3 1

ANGLES 30° - 45° - 60°

Tan Sin Cos
30° 1 1 3
3 = 0.577350 2 = 0.500000 2 = 0.866025

45° 1 1 1
2 = 0.707107 2 = 0.707107

60° 3 1
3 = 1.732051 2 = 0.500000
2 = 0.866025

56 Brooke
Cutting Tools Limited
Useful formulae for Finding
Dimensions of Circles, Squares, etc.

D is diameter of stock necessary to turn shape desired.

E is distance “across flats,” or diameter of inscribed circle.
C is depth of cut into stock turned to correct diameter.

TRIANGLE
C
E = side x 0.57735 E
D = side x 1.1547 = 2E
Side = D x 0.866 D
C = E x 0.5 = D x 0.25

SQUARE
E
E = side = D x 0.7071
D = side x 1.4142 = diagonal C
D
Side = D x 0.7071
C = D x 0.14645

PENTAGON
D
E = side x 1.3764 = D x 0.809
D = side x 0.7013 = E x 1.2361
Side = D x 0.5878 E C
C = D x 0.0955

HEXAGON
D
E = side x 1.7321 = D x 0.866
D = side x 2 = E x 1.1547
Side = D x 0.5 E C
C = D x 0.067

OCTAGON
D
E = side x 2.4142 = D x 0.9239
D = side x 2.6131 = E x 1.0824 C
Side = D x 0.3827
C = D x 0.038
E

Brooke
Cutting Tools Limited
57
Areas of
Plane Figures

SQUARE
d s
A = area
A = S² = 1/2 d²
S = 0.7071d = A s
d = 1.414S = 1.414 A

RECTANGLE
d a
A = area
A = ab = a d² - a² = b d² - b²
d = a² + b² b
a = d² - b² = A ÷b
b = d² - a² = A ÷a

RIGHT ANGLED TRIANGLE

a
A = area b
A = bc
2
a = b² + c² c
b = a² - c²
c = a² - b²

ACUTE ANGLED TRIANGLE

a
A = area c
h
²
bh b
A= 2 = 2 a² - (a² +2bb² )- c² b
1
if S = ( a + b + c ) then,
2
A= S(S -a) (S - b) ( S - c)

58 Brooke
Cutting Tools Limited
OBTUSE ANGLED TRIANGLE

A = area
c
bh
A= 2 =
b
2
a² ­ (c² -2ba² -)b² ² h
a
1
if S = ( a + b + c ) then,
2 b
A= S(S -a) (S - b) ( S - c)

CIRCLE

A = area C = circumference
A = r² = 3.1416 r²

d²
A= = 0.7854 d²
4 d
r
C = 2 r = 6.2832r = 3.1416d

r = C ÷6.2832 = A ÷3.1416 = 0.564 A

d = C ÷3.1416 = A ÷0.7854 = 1.128 A

REGULAR HEXAGON

A = area R
R = radius of circumscribed circle 60°

r = radius of inscribed circle

A = 2.598S² = 2.598R² = 3.464r² r
R = S = 1.155r
s
r = 0.866S = 0.866R

The construction of a regular hexagon forms six equilateral triangles,thus

the area of the hexagon can also be found by calculating the area of the
equilateral triangle and multiplying the result by six.

Brooke
Cutting Tools Limited
59
 To convert Multiply by

From To

hp kw 0.7457
Kw hp 1.3410

lbs/inch² kPa 6.8948

Kpa lbs/inch² 0.1450

m/min ft/min 3.2810

ft/min m/min 0.3048

inch mm 25.4
mm inch 0.03937

inch² cm² 6.45

cm² inch² 0.155

inch³ cm³ 16.39

cm³ inch³ 0.061

kg lbs 2.2046
lbs kg 0.4536

gallons litres 4.546

litres gallons 0.22

60 Brooke
Cutting Tools Limited
Castle Brooke Tools (UK) Ltd
Princess Street
South Yorkshire
Sheffield,UK
S4 7UU

T: +44 (0) 114 261 7200

F: +44 (0) 114 261 7370
E: [email protected]
www.castlebrooke.co.uk