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