LESSON FOUR: CALCULATIONS IN

TURNING OPERATIONS
Dr Adiat I. Arogundade

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 Objectives
At the end of this lesson, the learner should be
able to:
• Calculate the feed, depth of cut, feed rate,
cutting speed and power for the single tooth
cutting operation such as turning and boring
• Calculate the feed, depth of cut, feed rate,
cutting speed and power for the multiple
tooth cutting operation such as milling and
drilling
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 Turning Operation

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 What are turning operations
• Turning operations are all operations
performed on the lathe to create rotational
parts by the rotary motion of the work piece
against a stationary work tool. They include:

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 Feed

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 Cutting speed
This is the surface speed of the work piece at
the tool tip.
 It may also be described as the tangential
speed of the work piece.

π (3.14): Circular constant

Dm (mm): Diameter of work piece
n (rev/ min-1): Spindle speed

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 Worked Example
• A 75 mm diameter bar is being turned on a
lathe making 120 rev/min. Calculate the
cutting speed.

𝜋 𝐷𝑁 𝜋 ( 75 ) ( 120 )
𝑉 𝑐= = =28 𝑚 / 𝑚𝑖𝑛
1000 1000

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 Spindle speed-Worked Example
• A 50 mm diameter bar is to be turned at a
cutting speed of 25 m/min. Find the lathe
spindle speed required.

• Generally, the spindle speed can be estimated

as

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 Selecting the right spindle speed
• A mild steel bar, 25 mm is to be turned at a
cutting speed of 25 m/min. The spindle speeds
available on the lathe are 45, 80, 110, 190,
250, 400, 600 and 1000 rev/min. which N
should be chosen?

• Therefore, lathe spindle speed selected will be

250 rev/min.

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 Designing the spindle speed train
• Suppose we wish to design a lathe to take
work from 10 mm dia. to 200 mm dia. Where
the cutting speed is fixed at 20 m/min. The
gear design can be done by arithmetic
progression or geometric progression.
However, the often preferred method is the
geometric progression.

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 Arithmetic progression design of spindle
speed
• The fastest speed and the lowest speed are
fixed.
• Fastest speed:
• Lowest speed:
• Assuming we design for an 8-speed gear then
we need to fix 6 more speeds between the
lowest and the fastest speed.

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 Arithmetic progression design of spindle
speed
• In arithmetic progression, there will be equal
intervals between the speeds. For eight
speeds, we have 7 intervals. Therefore:

• Kindly complete the problem by listing out the

eight speeds.

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 Geometric progression design of spindle
speed
• Each speed is a multiple of the previous, so for
8-speed train with 600 rev/min as the highest
speed, the interval is gotten as:

• Complete the speeds in this interval

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 Calculating Cutting time
• A cylindrical job of 100 mm diam.is to be
turned at a cutting speed of 22 m/min, the
feed being 2 mm/rev. If the length of the job is
150 mm, find the time for one cut.
• If it does 2 mm/rev, then a 150 mm bar will be
turned in
• How many revolutions will it turn in a minute
(N)

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 Calculating Cutting time

• Or
• 2 mm in one revolution (feed)
• Total no of revolutions in one minute 70 rev
• Therefore, distance covered in 1 min, 140 mm
• Therefore time taken for 150 mm,

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 Volume of Metal Removed

• Given a turning process with the following

parameters:
– cutting speed (s m/min)
– depth of cut (d mm)
– Feed (f mm/rev)
If the surface area of the chip is given by (f x d) mm2
In 1 min, the length of chip removed will be s meters
Therefore, the volume of metal removed will be
(1000xsxdxf) mm3
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 Example

• Given the following cutting parameters

• Cutting speed, s = 25 m/min
• Feed, f = 1.5 mm/rev, depth of cut, d = 3 mm
• Volume of metal removed per minute, V
• /min
• The volume of metal removed per minute is
called the metal removal rate.

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 Metal removal rate

• The metal removal rate (cm3/min) is limited

by the driving power that the motor is able to
develop and also by the nature of the
material. Ductile (softer) materials can be
removed at a higher volume rate while brittle
materials (harder) require more power
(kilowatt).

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Metal removal per kilowatt of some metals

Material Maximum metal removal rate per

kilowatt ( cm3/min)
Steel 15
Cast iron 18
Copper 36
Aluminum 54
Brass 15
Lead

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 Cutting Power

• A machine is capable of removing 15cm3 of

steel in a minute per kilowatt of driving power.
Calculate how much power is needed to
remove 30 cm3 of steel in one minute.

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 Cutting Power- Ex2

• A turning operation had a cutting speed of 30

m/min, a feed of 2 mm/rev and a depth of 4
mm. Find the power used during cutting if
maximum removal rate per kilowatt is 18
cm3/min.

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 Milling Operations

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 Turning Vs Milling
Turning Milling

Turning is performed to generate a cylindrical or Milling is performed primarily to generate a flat

conical surface. surface.

Turning process utilizes a single point cutting tool, Milling process utilizes a multi-point cutting tool,
called SPTT (Single Point Turning Tool). called milling cutter.

In turning, cutting tool continuously remains in In milling, tooth continuously engages and
contact with work piece during the operation. disengages during operation (intermittent cutting).

Here the work piece is rotated at fixed revolution Here the cutter is rotated at fixed revolution per
per minute (RPM). This rotation provides necessary minute (RPM). Rotating cutter provides necessary
cutting velocity. cutting velocity.

In turning, feed motion is derived by moving the In milling, feed motion is derived by moving the
cutting tool (tool carriage). work piece (worktable).

It can produce fragmented, discontinuous, or

continuous chips (based on work and tool Milling inherently produces discontinuous chips.
materials, cutting parameters, etc.).

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 Milling Calculations
• A 150 mm dia. milling cutter is revolving at 40
rpm. Calculate the cutting speed.
Here the cutter rather than the work piece is the
focus.

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 Feeds in milling
• In milling, feed is usually quoted as mm/tooth
while the total feed becomes mm/rev as
obtains in turning.
Net feed (mm/rev) = no of teeth x feed (mm/tooth)
A milling cutter has 12 teeth and a feed of 0.15
mm/tooth. If the spindle speed is 90 rev/min, calculate
the feed:
1. In mm/rev
2. In mm/min

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 Feeds in milling
• 1. Feed in mm/rev =

• 2. Feed in mm/min = f mm/rev x spindle speed

•

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