3.

Calculations of cutting conditions for milling operation

Sketch of milling operation is shown in Figure 3.1 (see book [1], Fig. 4.10, page
116). Workpiece material is high-quality steel 20X2H4A (20H2N4A) in normalised
condition with HB 256 and σu = 880 MPa.

40 Milling
11 Rz20
4 slots 6+0.12

59.1–0.25 1. Mill 4 slots 11.

Figure 3.1 – Sketch for milling operation

3.1. Selection of diagram and cutter for milling operation

Diagram for machining in the milling operation 40 is selected from Figure 3.1
[2] with application of slotting mill. Geometric configuration of machined piece al-
lows application of disk-type slotting cutter (GOST 3964-69) of the larger diameter D
for the specified width of slot B = 6 mm [3] (Figure 3.2).
Parameters of the selected milling cutter
are:
- External diameter D = 63 mm by js16;
- Internal diameter d = 22 mm by H7;
- Width B = 6 mm by H9 selected;
- Number of teeth z = 16;
- Milling cutter material is Р6М5 (R6M5) selec-
ted from Table 3.7 [2] according to the type of
milling operation and selected configuration of
milling cutter for structural carbon steel as the
nearest to the workpiece material.
Figure 3.2 – Sketch of disk-type
slotting milling cutter
 2

3.2. Depth and width of milling

According to the diagram (ref. Figure 3.1 in) and Figure 3.1 the parameters are:
- depth of milling t = [A5max] + Z16max = 6.15 + 0.346 = 6.496 mm (ref. [1],
Table 4.5, equation 5);
- width of milling B = 6 mm.

3.3. Feed
Feed per tooth fz is selected according to the material and configuration of
milling cutter from Table 3.2 in [2] for smaller power of machine (up to 5 kW) due to
small element to be produced, structural steel to be machined, mills with coarse teeth
and middle stiffness of system workpiece–fixture
fz = 0.06 mm/tooth.
Cutting fluid 5-% emulsion from Укринол-1 (Ukrinol-1) emulsol is selected
from Table 1.3 [2].

3.4. Cutting velocity

The cutting velocity is considered to be equal to peripheral velocity of milling
cutter

= 33.857 m/min.

Values of coefficient CV and indexes of power are given in Table 3.7, and values
of tool life T – in Table 3.8 [2]:
Para- T,
CV q x y u p m kMV kSV kTV kcfV kV
meter min
Value 68.5 0.25 0.3 0.2 0.1 0.1 0.2 90 0.64 1.0 1.0 1.0 0.64

Total correction coefficient for cutting velocity that takes into account actual
cutting conditions [2]
kV = kMV × kSV × kTV × kcfV,
where kMV – coefficient describing the quality of workpiece material (Tables 3.9);
kSV – coefficient describing condition of workpiece surface (Table 3.13); kTV – coeffi-
cient describing the milling cutter material (Table 3.14); kcfV – coefficient taking into
account the application of cutting fluid (if the fluid is applied, kcfV = 1.0). For milling
the considerations for cutting fluids application are similar to those given in Para
1.9.7.
Coefficient of workpiece material
kMV = ≈ 0.64
where nV = 1.35, kG = 0.8, σu = 880 MPa for chromium-nickel steel 20X2H4A.
 3
Rotational speed is calculated from formula

= 161.04 rev/min,
where D – diameter of milling cutter, mm.

3.5. Cutting force

Main constituent of cutting force at milling is peripheral force

≈ 1284 N,

where z – number of milling cutter teeth; nc – calculated rotational speed of milling

cutter, mm/rev.
Values of coefficient CP and indexes of power are given in Table 3.15. Correc-
tion coefficient for quality of workpiece material kMP for steel and cast iron is given
in Table 3.16:
Parameter Cp x у и q w kMP
Value 68.2 0.86 0.72 1.0 0.86 0 1.05

Coefficient for quality of workpiece material

= 1.049,
where n = 0.3 for cutting with high-speed steel tool.

3.6. Torque
Torque of spindle for drive of milling cutter is calculated from

= 40.45 N·m,

3.7. Power of cutting

Effective power of cutting

= 0.668 kW.

Power of electric motor necessary for cutting is determined with a machine effi-
ciency coefficient (ηm = 0.75)
= 0.891 kW.

3.8. Selection of machine

 4
Milling machine is selected according to the recommendations of paragraph 3.8
in book [2] (Table 3.1).

Table 3.1 – Technical data of the selected horizontal milling machine 6Р80 (6R80)

Parameter Unit Value

Sizes of work zone:
- Dimensions of work surface of
table (width×length) mm 200×800
- Distance from axis of horizontal
spindle to table surface 20–320
Minimal and maximal values
mm/min 25–1120
of traverse feed
Number of feeds’ steps 12
Series (row) of feeds 25, 35.3, 49.9, 70.5, 99.6,
mm/min 140.8, 198.9, 281, 397,
561, 792.7, 1120
Minimal and maximal values of
rev/min 50–2240
spindle rotational speed
Number of rotational speed steps 12
Series (row) of spindle speeds 50, 70, 99, 141, 199, 281,
rev/min 397, 562, 794, 1122, 1585,
2240
Power of drive electric motor Nems kW 3

3.9. Agreement of rotational speed with technical data of milling machine

Adopted value is nm = 141 rev/min (nm ≤ nc = 161.04 rev/min).

3.10. Agreement of feed with technical data of milling machine

The calculated minute feed value is
fmc = fz z nm = 135.36 mm/min.
The selected minute feed value is
fmm = 140.8 mm/min (4 % larger than fmc).

3.11. Actual parameters of cutting process

Actual cutting velocity
= 27.89 m/min.

Actual feed per tooth fza is calculated with application of the minute feed agreed
with machine’s data
 5
fza = fmm /(z nm) = 0.0624 mm/tooth.
Actual main constituent of cutting force at milling is peripheral force

≈ 1321 N.

Actual torque of spindle for drive of milling cutter is calculated from

= 41.61 N·m,
Actual effective power of cutting

= 0.602 kW.

Actual power of electric motor necessary for cutting is determined with a ma-
chine efficiency coefficient (ηm = 0.75)
= 0.803 kW.

The results of calculations and selections are written down into Table
No. of
manufac- t, B, fmm, fza, mm/ n m, Va, m/ P , N Ma, Nema, Nems,
za
turing mm mm mm/min tooth rev/min min Nm kW kW
step
1 6.496 6 140.8 0.0624 141 27.89 1321 41.6 0.8 3

Conclusion
The calculated and assigned parameters for milling operation, technical data of
selected machine will ensure reliable and effective cutting process (Nems ≥ Nema) for
producing the quality products.

References
1. Planning of Manufacturing Metal-Cutting Processes. Calculations of Opera-
tion Dimensions: Manual to Term Projects / M. K. Knyazyev, S. E. Markovych,
B. S. Bilokon. – Kharkiv: M. Ye. Zhukovsky National Aerospace University
“Kharkiv Aviation Institute”, 2016. – 144 p.
2. Білоконь Б. С. Розрахунки режимів різання токарної, свердлильної й
фрезерної операцій: навч. посібник (англ. мовою) / Б. С. Білоконь, М. К. Князєв.
– Х.: Нац. аерокосм. ун-т «Харк. авіац. ін-т», 2009. – 83 с. (Bilokon B. S. Calcula-
tions of Cutting Conditions for Turning, Drilling and Milling Operations: Teaching
Aid (in English) / B. S. Bilokon, M. K. Knyazyev. – Kharkiv: M. Ye. Zhukovsky Na-
tional Aerospace University “Kharkiv Aviation Institute”, 2009. – 83 p.)
3. Справочник технолога-машиностроителя. В 2-х т. Т. 2 / Под ред.
А. Г. Косиловой и Р. К. Мещерякова. – 4-е изд., перераб. и доп. – М.:
Машиностроение, 1985. – 496 с. (Handbook of Production Engineer in Machine-
 6
Building. In 2 volumes. V. 2 / Editorship of A. G. Kosilova and R. K. Mescheryakov.
– the 4-th edition, revised and added. – Moscow: Mashinostroyenie, 1985. – 496 p.)