STARTING RECIPES

Tormach - Aluminum
Tool: Lakeshore 3-Flute, 1/4" http://www.lakeshorecarbide.com/14variablefluteendmillforalumi

Holder: TTS Set Screw https://www.tormach.com/store/index.php?app=ecom&ns=prods

Tips: 1) Tool does not need a "weldon flat"

2) Choke up on tool! (only the flutes should be stickout out of the holder) - see example at http://i
3) Replace the Tormach set screw with McMaster p/n 92311A556 (1/4x28 Stainless Set Screw).
4) Tool has a 0.003" - 0.005" Corner Radius (eliminates weakest part of tool)

Starting DOC: 0.25" 50% - 100%

Starting WOC: 0.05" 20% of Diameter (a.k.a. optimal load in Fusion 360 Adaptive Toolpath)

IPT: 0.002 Do not go less than this! [Absolute minimum: 0.0005"]

IPM: 30.6

SFM: 334
RPM: 5,100

Tormach - Steel
Tool: Lakeshore 5-Flute, 1/4" http://www.lakeshorecarbide.com/14variable5fluteendmillforstain

Holder: TTS Set Screw https://www.tormach.com/store/index.php?app=ecom&ns=prods

Tips: 1) Tool does not need a "weldon flat"

2) Choke up on tool! (only the flutes should be stickout out of the holder) - see example at http://i
3) Replace the Tormach set screw with McMaster p/n 92311A556 (1/4x28 Stainless Set Screw)
4) Despite saying "Stainless", this Lakeshore endmill *IS* great for mild steel
5) Use "stubby" tools!

Starting DOC: 0.25"

Starting WOC: 0.05" (a.k.a. optimal load in Fusion 360 Adaptive Toolpath)

IPT: 0.001" DO NOT go less than this! [Absolute minimum: 0.0005"]

IPM: 15.3"

SFM: 200
RPM: 3,050
om/14variablefluteendmillforaluminumzrn.aspx

e/index.php?app=ecom&ns=prodshow&ref=31818&portrelay=1

he holder) - see example at http://imgur.com/a/74aUk

56 (1/4x28 Stainless Set Screw). Larger Tormach Set Screw holders use 3/8x24 (McMaster 92311A635)
st part of tool)

Adaptive Toolpath)

om/14variable5fluteendmillforstainlesssteelstublength.aspx

e/index.php?app=ecom&ns=prodshow&ref=31818&portrelay=1

he holder) - see example at http://imgur.com/a/74aUk

56 (1/4x28 Stainless Set Screw)
t for mild steel
Milling Speeds & Feeds - Imperial/Inch

BY SFM OR BY RPM DRILLING

INCH
SFM 225 SFM 2,356 SFM 152
Tool Diameter 0.250 Tool Diameter 0.500 Tool Diameter 0.3860
IPT 0.00200 IPT 0.01000 IPR (Inch per Rev) 0.00579
# Flutes 5 # Flutes 2 RPM 1,500
RPM 3,438 RPM 18,000 Feed (IPM) 8.7
Feed (IPM) 34.4 Feed (IPM) 360.0 HSS: 100-200 SFM

Speeds & Feeds: Depth of Cut, Width of Cut

Diameter Low High Start at
DOC: 0% up to 200% of diamater 0.2500 0.000 0.500 0.25
WOC 5% up to 25% of diamater 0.2500 0.013 0.063 0.050

Exceptions:
Toolings smaller than 1/8" (3mm): different rules apply. Less DOC, WOC; chip evacuation, sometimes IPT gets really low. Harvey Tool = experts
Shear Hog: 0.2" WOC, 0.2" DOC
More flutes = stronger, but reduce WOC to aid in chip evacuation
Steel: SLOW (low) SFM, keep 0.001" IPT
Aluminum: Higher SFM, keep 0.001" IPT

Material Removal Rate & Horsepower Estimate

IPM DOC WOC MRR (cu in) Material K Factor Est. Horsepower
34.4 0.25 0.050 0.43 6061-T6 Aluminum 3.34 0.13

255.0 0.875 0.125 27.89 6061-T6 Aluminum 3.34 8.34

Formulas to Know!
Feed = RPM * CPT * Flutes
SFM = (Pi * RPM * Dia) / 12
RPM = (12*SFM) / (Pi * diameter)
MRR = WOC * DOC * IPM
HP = MRR / K [Note: HP at cutter]

Milling Speeds & Feeds - Metric

METRIC
BY SFM OR BY RPM DRILLING
Vc [m/min] 91 Vc [m/min] 12 Vc [m/min] 4
Tool Diameter [mm] 6.350 Tool Diameter [mm] 12.700 Tool Diameter [mm] 0.5000
Vz [mm/Z] 0.05080 Vz [mm/Z] 0.01778 VZ (rev!) 0.05080
# Flutes 4 # Flutes 4 RPM 2,800
RPM 4,584 RPM 300 Feed [mm/min] 142.2
Feed (mm/min) 931.4 Feed (mm/min) 21.3 HSS: 30-30 SFM

Speeds & Feeds: Depth of Cut, Width of Cut

Diameter Low High
DOC: 0% up to 200% of diamater 6.3500 0.000 12.700
WOC 5% up to 25% of diamater 6.3500 0.318 1.588

Zig Zag Method

Pi 3.141593

Zig Zag Summary:

1) Find conservative starting point - e.g. a baseline cut that is making a good chip and machine is happy.
If you have no idea where to start, try 1,000 RPM and a 0.00075 chipload per tooth
2) Increase RPM, keep chipload constant (so higher feedrate!)
3) If #2 is OK, then try higher chipload (same RPM). So again, this means a higher feedrate!
4) If #3 is OK, then back to #2 - e.g. increase RPM and continue process of zig/zag between increasing RPM and Chipload
DRILL HORSEPOWER CALCULATION
HP = (FPR * SFM * Diameter * Specific Cutting Force) / 132,000

D 0.9 Drill Diameter

f 0.0046 Feed Per Revolution
3.0 Inches Per Minute (Feed)
Vc 154 Surface Feet per Minute
RPM 654
Kc 94,500 Specific Cutting Force (Lbf/Inch^2) (From P. ___ of Sandvik Tech Guide)
Force to cut a chip area of 1 mm² and thickness of 1 mm
Machine Efficiency 80%
HP 0.46
MRR 1.91

Test Cuts with 0.5" Drill (12.7MM)

Cut # SFM IPR HP RPM IPM Dia MRR
1 153 0.0046 0.25 1,175 5.5 0.5 1.06
2 153 0.010 0.55 1,175 11.75 0.5 2.31
3 200 0.010 0.72 1,527 15.27 0.5 3.00
4 250 0.010 0.89 1,909 19.1 0.5 3.75
5 300 0.010 1.07 2,291 22.9 0.5 4.50
6 300 0.012 1.29 2,291 27.5 0.5 5.40
7 400 0.01 1.43 3,050 31 0.5 5.99

MRR = (IPR * RPM) * pi * R^2

Video Notes on Drilling

Goal of video: how hard can we push a drill, if/when it's a good tool, how much HP does it take!

Why drills?
Relatively cheap! McMaster 1/2" HSS only $8.72: 2896A43
Rake (face of tool) is designed to cut axially; flutes help pull chips up. Axially stiff. IOW: great for "plunging" (better
Great for pre-drilling into pockets to avoid slow/dangerous ramping with end mills OR you can use them to gang-dril
G-Wizard, LMS (http://littlemachineshop.com/reference/cuttingspeeds.php) or Machinery's Handbook
Great MRR (again, given tool cost, machine rigidity and handling "deep" cuts)
Drill before you machine away to create tighter inside corner
McMaster 150 degree carbide!
Sandvik Tech Guide)

diameter 0.5
radius 0.25
radius ^2 0.0625

pi 3.141593
area of circle 0.20

IPR 0.0046
RPM 1175
IPM 5.405

1.061269

W: great for "plunging" (better then end mills!)

you can use them to gang-drill pockets (think 2" deep pocket). AND I've even see folks gang-drill along a slot to avoid slotting
ery's Handbook
o avoid slotting
Spreadsheet Used for Wednesday Widget 175: Comparing Drills in Steel
DRILL HORSEPOWER CALCULATION
HP = (FPR * SFM * Diameter * Specific Cutting Force) / 132,000

D 0.46875 Drill Diameter

f 0.006 Feed Per Revolution
3.9 Inches Per Minute (Feed)
Vc 80 Surface Feet per Minute
RPM 652
Kc 216,500 Specific Cutting Force (Lbf/Inch^2) (From Sandvik Rotating Tools PDF P. J 482)
Force to cut a chip area of 1 mm² and thickness of 1 mm
Machine Efficiency 80%
HP 0.46
MRR 0.68

Tool: HSS Twist Drill

Manufacturer N/A Price
Vendor McMaster P/N 2901A139 $10.24
Alternative McMaster P/N 8870A43 (Uncoated) for $8.41

Diameter 0.46875 inches

Diameter 11.91 mm
Flutes 2

Starting S&F: Mild Steel

SFM 80
RPM 652
Inch/Rev 0.006
IPM 3.9

Test Cuts: HSS Twist Drill

Cut # SFM IPR HP RPM IPM Dia MRR
1 80 0.006 0.46 652 3.9 0.46875 0.68
2 100 0.008 0.77 815 6.5 0.46875 1.13
3 100 0.01 0.96 815 8.1 0.46875 1.41
4 125 0.01 1.20 1,019 10.2 0.46875 1.76
5 150 0.01 1.44 1,222 12.2 0.46875 2.11
 6 125 0.012 1.44 1,019 12.2 0.46875 2.11
7 125 0.011 1.32 1,019 11.2 0.46875 1.93

MRR = (IPR * RPM) * pi * R^2

aring Drills in Steel

Rotating Tools PDF P. J 482)

Tool: Insert Drill

ManufactuUltra-Dex Price
Vendor Shars P/N 420-3457 $120.70
Inserts Shars P/N 424-1967 $14.12
NOTE: Drill body (P/N 420-3457 does *not* come with inserts)
Diameter 0.625 inches
Diameter 15.88 mm
Flutes 2

Manufacturer Recommended Starting S&F: Mild Steel

SFM 225 650
RPM 1,375 3,973
Inch/Rev 0.0022 0.006
IPM 3.0 23.8

NOTES:
1) We do not have thru-spindle-coolant
2) Drill can only drill 2x diameter. For a 5/8" drill, that means no deeper than 1.25"

Test Cuts - UltraDex Carbide Insert Drill

Cut # SFM IPR HP RPM IPM Dia MRR
1 225 0.0022 0.51 1,375 3 0.625 0.93
2 225 0.003 0.69 1,375 4.1 0.625 1.27
3 300 0.0025 0.77 1,833 4.6 0.625 1.41
4 400 0.002 0.82 2,445 4.9 0.625 1.50
5 150 0.0015 0.23 917 1.4 0.625 0.42
 6 125 0.0022 0.28 764 1.7 0.625 0.52

MRR = (IPR * RPM) * pi * R^2

Drilling 304 Stainless
Cobalt (NEEDS TO BE COBALT - not HSS!)
45 SFM
0.003 FPR
Full depth OR big pecks - e.g. 1x diameter
DeWalt CoBalt drills (lowes) are fine! (regular 135 degree, not of those started tips)

Carbide
75 SFM
0.003 FPR
Full depth OR big pecks - e.g. 1x diameter

135 angle drill

CARBIDE may break, cobalt is actually BETTER!
Center drill 0.030" deep; requires larger angle or the same (e.g. 140 degree center drill)
Make sure first peck isn't shallow!!!!

1/8" or smaller requires carbide.

Thin stainless (<0.1875") - your metal is twice as strong because the skin is on both sides. The thicker you go, the m
Oddly, sheet metal can be more challenging to drill than bar stock

Machining 304 Stainless

1/4 Variable 5 Flute End Mill for Stainless Steel

http://www.lakeshorecarbide.com/14variable5fluteendmillforstainlesssteel.aspx
Use for outside profiling, clean up. DO NOT helical ramp
200 SFM
0.002 IPT
20% WOC
Max 0.25" DOC

1/4 Variable Flute End Mill for Steel

http://www.lakeshorecarbide.com/14variablefluteendmillforsteel.aspx
Use for Stainless Internal pockets and/or any helical ramping
225 SFM
0.001 IPT
10% WOC
Max 0.1875" DOC
ides. The thicker you go, the more easy (gummy) the center is.
Radial Chip Thinning!
Constant Diameter Radial Stepover Diameter/Radial Stepover
0.5 0.5 0.02 25.00

0.5 0.5 0.015 33.33

0.5 0.25 0.017 14.71

0.5 0.25 0.01 25.00

Great Sandvik YouTube Video discussing and demonstrating this:

https://www.youtube.com/watch?v=4Q4yRt1jHGo

IPT (Actual) Shows the Effect of Chip Thin

44
.00
0 42
00
0. 4 0
00
0. 3 8
00
0. 3 6
00
0. 3 4
00
0. 3 2
00
0. 3 0
00
0. 2 8
00
0. 2 6
00
0. 2 4
00
0. 2 2
00
0. 2 0
00
0. 1 8
00
0. 1 6
00
0. 1 4
00
0. 1 2
00
0. 1 0
00
0. 0 8
00
0. 0 6
00
0. 0 4
00
0. 0 2
00
0. 0 0
00 5 2 9 6 3 1 7 4 1 8 5 2 9 6 3 8 7 4 1 8 5 2 9 6 3 5 7
0. .12 .12 .11 .11 .11 0.1 .10 .10 .10 .09 .09 .09 .08 .08 .08 0.0 .07 .07 .07 .06 .06 .06 .05 .05 .05 0.0 .04 .04
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Graph Data
Constant Diameter Radial Stepover Diameter/Radial Stepover
0.5 0.5 0.125 4.00
0.5 0.5 0.124 4.03
0.5 0.5 0.123 4.07
0.5 0.5 0.122 4.10
0.5 0.5 0.121 4.13
0.5 0.5 0.12 4.17
0.5 0.5 0.119 4.20
0.5 0.5 0.118 4.24
0.5 0.5 0.117 4.27
0.5 0.5 0.116 4.31
0.5 0.5 0.115 4.35
0.5 0.5 0.114 4.39
0.5 0.5 0.113 4.42
0.5 0.5 0.112 4.46
0.5 0.5 0.111 4.50
0.5 0.5 0.11 4.55
0.5 0.5 0.109 4.59
0.5 0.5 0.108 4.63
0.5 0.5 0.107 4.67
0.5 0.5 0.106 4.72
0.5 0.5 0.105 4.76
0.5 0.5 0.104 4.81
0.5 0.5 0.103 4.85
0.5 0.5 0.102 4.90
0.5 0.5 0.101 4.95
0.5 0.5 0.1 5.00
0.5 0.5 0.099 5.05
0.5 0.5 0.098 5.10
0.5 0.5 0.097 5.15
0.5 0.5 0.096 5.21
0.5 0.5 0.095 5.26
0.5 0.5 0.094 5.32
0.5 0.5 0.093 5.38
0.5 0.5 0.092 5.43
0.5 0.5 0.091 5.49
0.5 0.5 0.09 5.56
0.5 0.5 0.089 5.62
0.5 0.5 0.088 5.68
0.5 0.5 0.087 5.75
0.5 0.5 0.086 5.81
0.5 0.5 0.085 5.88
0.5 0.5 0.084 5.95
0.5 0.5 0.083 6.02
0.5 0.5 0.082 6.10
0.5 0.5 0.081 6.17
0.5 0.5 0.08 6.25
0.5 0.5 0.079 6.33
0.5 0.5 0.078 6.41
0.5 0.5 0.077 6.49
0.5 0.5 0.076 6.58
0.5 0.5 0.075 6.67
0.5 0.5 0.074 6.76
0.5 0.5 0.073 6.85
0.5 0.5 0.072 6.94
0.5 0.5 0.071 7.04
0.5 0.5 0.07 7.14
0.5 0.5 0.069 7.25
0.5 0.5 0.068 7.35
0.5 0.5 0.067 7.46
0.5 0.5 0.066 7.58
0.5 0.5 0.065 7.69
0.5 0.5 0.064 7.81
0.5 0.5 0.063 7.94
0.5 0.5 0.062 8.06
0.5 0.5 0.061 8.20
0.5 0.5 0.06 8.33
0.5 0.5 0.059 8.47
0.5 0.5 0.058 8.62
0.5 0.5 0.057 8.77
0.5 0.5 0.056 8.93
0.5 0.5 0.055 9.09
0.5 0.5 0.054 9.26
0.5 0.5 0.053 9.43
0.5 0.5 0.052 9.62
0.5 0.5 0.051 9.80
0.5 0.5 0.05 10.00
0.5 0.5 0.049 10.20
0.5 0.5 0.048 10.42
0.5 0.5 0.047 10.64
0.5 0.5 0.046 10.87
0.5 0.5 0.045 11.11
0.5 0.5 0.044 11.36
0.5 0.5 0.043 11.63
0.5 0.5 0.042 11.90
0.5 0.5 0.041 12.20
0.5 0.5 0.04 12.50
0.5 0.5 0.039 12.82
0.5 0.5 0.038 13.16
0.5 0.5 0.037 13.51
0.5 0.5 0.036 13.89
0.5 0.5 0.035 14.29
0.5 0.5 0.034 14.71
0.5 0.5 0.033 15.15
0.5 0.5 0.032 15.63
0.5 0.5 0.031 16.13
 0.5 0.5 0.03 16.67
0.5 0.5 0.029 17.24
0.5 0.5 0.028 17.86
0.5 0.5 0.027 18.52
0.5 0.5 0.026 19.23
0.5 0.5 0.025 20.00
0.5 0.5 0.024 20.83
0.5 0.5 0.023 21.74
0.5 0.5 0.022 22.73
0.5 0.5 0.021 23.81
0.5 0.5 0.02 25.00
0.5 0.5 0.019 26.32
0.5 0.5 0.018 27.78
0.5 0.5 0.017 29.41
0.5 0.5 0.016 31.25
0.5 0.5 0.015 33.33
0.5 0.5 0.014 35.71
0.5 0.5 0.013 38.46
0.5 0.5 0.012 41.67
0.5 0.5 0.011 45.45
0.5 0.5 0.01 50.00
0.5 0.5 0.009 55.56
0.5 0.5 0.008 62.50
0.5 0.5 0.007 71.43
0.5 0.5 0.006 83.33
0.5 0.5 0.005 100.00
0.5 0.5 0.004 125.00
0.5 0.5 0.003 166.67
0.5 0.5 0.002 250.00
0.5 0.5 0.001 500.00

Fusion 360 Graphic

Stepover 50%
End Mill 0.25
Starting WOC: 0.125
IPT: 0.001
RPM: 5,100
IPM: 15.3
 IPT (Programmed) IPT (Actual) "Tenths"
0.0025 0.0009797959 9.8

0.0045 0.0015 15.4

0.001 0.0005 5.0

0.001 0.0004 3.9

ows the Effect of Chip Thinning!

7 4 1 8 5 2 9 6 3 5 7 4 1 8 5 2 9 6 3 2 7 4 1 8 5 2
07 07 06 06 06 05 05 05 0.0 .04 .04 .04 .03 .03 .03 .02 .02 .02 0.0 .01 .01 .01 .00 .00 .00
0. 0 . 0. 0. 0 . 0. 0. 0 . 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
IPT (Programmed) IPT (Actual)
0.005 0.0043
0.005 0.0043
0.005 0.0043
0.005 0.0043
0.005 0.0043
0.005 0.0043
0.005 0.0043
0.005 0.0042
0.005 0.0042
0.005 0.0042
0.005 0.0042
0.005 0.0042
0.005 0.0042
0.005 0.0042
0.005 0.0042
0.005 0.0041
0.005 0.0041
0.005 0.0041
0.005 0.0041
0.005 0.0041
0.005 0.0041
0.005 0.0041
0.005 0.0040
0.005 0.0040
0.005 0.0040
0.005 0.0040
0.005 0.0040
0.005 0.0040
0.005 0.0040
0.005 0.0039
0.005 0.0039
0.005 0.0039
0.005 0.0039
0.005 0.0039
0.005 0.0039
0.005 0.0038
0.005 0.0038
0.005 0.0038
0.005 0.0038
0.005 0.0038
0.005 0.0038
0.005 0.0037
0.005 0.0037
0.005 0.0037
0.005 0.0037
0.005 0.0037
0.005 0.0036
0.005 0.0036
0.005 0.0036
0.005 0.0036
0.005 0.0036
0.005 0.0036
0.005 0.0035
0.005 0.0035
0.005 0.0035
0.005 0.0035
0.005 0.0034
0.005 0.0034
0.005 0.0034
0.005 0.0034
0.005 0.0034
0.005 0.0033
0.005 0.0033
0.005 0.0033
0.005 0.0033
0.005 0.0032
0.005 0.0032
0.005 0.0032
0.005 0.0032
0.005 0.0032
0.005 0.0031
0.005 0.0031
0.005 0.0031
0.005 0.0031
0.005 0.0030
0.005 0.0030
0.005 0.0030
0.005 0.0029
0.005 0.0029
0.005 0.0029
0.005 0.0029
0.005 0.0028
0.005 0.0028
0.005 0.0028
0.005 0.0027
0.005 0.0027
0.005 0.0027
0.005 0.0026
0.005 0.0026
0.005 0.0026
0.005 0.0026
0.005 0.0025
0.005 0.0025
0.005 0.0024
0.005 0.0024
0.005 0.0024
0.005 0.0023
0.005 0.0023
0.005 0.0023
0.005 0.0022
0.005 0.0022
0.005 0.0021
0.005 0.0021
0.005 0.0021
0.005 0.0020
0.005 0.0020
0.005 0.0019
0.005 0.0019
0.005 0.0018
0.005 0.0018
0.005 0.0017
0.005 0.0016
0.005 0.0016
0.005 0.0015
0.005 0.0015
0.005 0.0014
0.005 0.0013
0.005 0.0013
0.005 0.0012
0.005 0.0011
0.005 0.0010
0.005 0.0009
0.005 0.0008
0.005 0.0006
0.005 0.0004
RPM
SFM
WOC
DOC
MRR
HP
John's Tips:
Matching Brinell is what drives K-Value
McMaster Carr has good chart for material hardness

Common Materials
1018
4140 alloy steel
A2 Tool steel 200-230
304 stainless cold rolled
6061-T6 Aluminum
7075-T6 Aluminum

Material
Very soft low-carbon steel
very low-carbon steel
Free cutting magnetic steels
1108, 1109, 1115, 1117, 1118, 1120, 1126, 1211 plain carbon steels
1108, 1109, 1115, 1117, 1118, 1120, 1126, 1211, plain carbon steels
1144 carbon steel cold rolled
11L17, 11L18, 12L13, 18, 12L13, 12L14, leaded carbon steels
11L17, 11L18, 12L13, 12L14 Leaded carbon steels
11L17, 11L18, 12L13, 12L14 Leaded carbon steels
1212, 1213, 1215, Plain carbon steels
A36, 44W hot rolled steels
low carbon steel 5-20Rc
structrul steel, ordinary low to medium carbon steel (0-5%c)
ASTM A516-70 Pressure vessel steel
1015, Ck15, C16,
1018
1035, c35 cold drawn
1043, 1045, C45, Hot Rolled
1148
plain high carbon steel
1055, 1060, 1064, 1065, 1070, 1074, 1078, 1080, 1084, 1086, 1090, 1095, 1548-1566
1055, 1060, 1064, 1065, 1070, 1074, 1078, 1080, 1084, 1086, 1090, 1095, 1548-1566
1055, 1060, 1064, 1065, 1070, 1074, 1078, 1080, 1084, 1086, 1090, 1095, 1548-1566
1055, 1060, 1064, 1065, 1070, 1074, 1078, 1080, 1084, 1086, 1090, 1095, 1548-1566
low alloy steel medium-hard
4130 alloy steel
4130 PH alloy steel
8620 alloy steel
8620 HT alloy steel
high-carbon and alloy steel medium-hard
4140 alloy steel
4140PH Alloy steel
4150 Alloy steel
5160 Alloy spring steel
6150 Alloy spring steel
low carbon steel
low carbon steel
high-strength structual steel
1132, 1137, 1139, 1140, 1144, 1146, 1151
1132, 1137, 1139, 1140, 1144, 1146, 1151
1132,1137, 1139, 1140, 1144, 1146, 1151
A514, T-1
armox 370T
armox 440
armox 500T
armox 600T
armox advance
astralloy 4800
astralloy 8000
astralloy Rol-man
astralloy -v EB-450
weldox 1030-1100
weldox 700
weldox 900/960
normal tool steels. Hard- quenching an tempering steel
low carbon steel 5-20Rc
01 Tool steel
S7 Tool steel
uddeholm Tool Steel
ame
caldie
dievar annealed
sleipner
sverker3, alsi d6, alsi d3
UHB 11 (alsi 1158)
unimax
vanadais 10 superclean
vanadais 6,23,30 ALSI superclean
vanadais 60 superclean
vancron 30,40 superclean
high-alloy, high hardness steel
300M alloy steel annealed
4340 alloy steel
4340 PH alloy steel
A2 Tool steel 200-230
AerMet 100, 310, 340, Alloy steel annealed
D2 Dc53 Tool Steel annealed
H13 Tool Steel
P20 Tool Steel
SB Wear
high-strength, hardned Tool and HSS steel.
300mAlloy steel hadrened
AerMet 100, 310, 340, Alloy steel annealed
D2, DC53 Tool Steel
D2, DC53 Tool Steel
D2, DC53 Tool Steel
D2, DC53 Tool Steel
D2, DC53 Tool Steel
D2, DC53 Tool Steel
H13 Tool Steel
H13 Tool Steel
H13 Tool Steel
H13 Tool Steel
H13 Tool Steel
H13 Tool Steel
Hardox 500
M1, M2, M6, M10, T1, T2, T6
S7 Tool steel
S7 Tool steel
S7 Tool steel
S7 Tool steel
toolox 33
Toolox 40
Toolox 44
High Speed Steel
M1, M2, M6, M10, T1, T2, T6
M3-1, M4, M7, M30, M33, M36, M41, M42, M43, M36, M41, M42, M43, M44, M46, M47, T5, T8
T15 M3-2
Powdered metals
anvioy 1150
free-cutting stainless steel
1.2085 stainless
302 Stainless
303 Stainless
416 Stainless
416 Stainless
416 Stainless
430F Stainless
moderately difficuit stainless steel
13-8 Aged h1025 Stainless
13-3 aged H1150 Stainless
15-5 PH H1150 Stainless
17-4 ph Stainless 150-200
17-4 ph Stainless
304 stainless cold rolled
316 Stainless
321 Stainless
410 Stainless steel annealed
422 Stainless
440 Stainless
CPM-154 Stainless Annealed
CPM-s30V-S35VN Stainless Annealed
Duplex 2205 (UNS S32205 / S31803)
Nitronic 50
Nitronic 60
13-8 aged h950 stainless
15-5 ph 1025-h1075
15-5 ph p 900 stainless
17-4 aged H1075 Stainless
17-4 aged h900 stainless
410 Stainless steel annealed
440 Stainless
440n stainless
CPM-154 Stainless Annealed
cpm-S90V stainless
p550 stainless
cast iron Sg iron
cast iron Sg iron
cast iron
cast iron
aluminum alloys
2024-t4
3003
5000
6061-t4
6061-t6
6063-t5,t6
7075-t6
alumec 89
cast aluminum
cast aluminum hi
cast aluminum 200, 500, 700 ,800
Wrought Aluminum 3000, 5000, 6000, 7000
sodt non-ferrous alloys
magnesium
zinc
copper alloys
c10100 copper
c18200 chrome copper
c18200 chrome copper
c863000 maganese bronze
c90300, c9220, c90500 tin bronze alloy
c90700 tin bronze (SAE 65)
c93200 sae 660
c95500 nickel aluminum bronze
copper 110
high lead brass
low lead brass
low lead brass
high alloyed copper
ampcoloy 83
ampcoloy 88
ampcoloy 940,95,972
ampcoloy 944 moldmate 90
tough2
tough 3
ampco aluminum bronze
ampco 18
ampco 21
amco 22
ampco 25
ampco 26
ampco 8
ampco m4
ferrous superalloy
nitronic 50
nitronic 60
nickel an colbalt super alloys
hastelloy b-3
hastelloy c c276
hastelloy x
inconel 600
inconel 700
invar 46
monel k 500
waspaloy
plastic, soft non-metals
acrylic
delrin, nylon, nylatron
duration xp, vespel pc , celazole pbi
HDPE, UHMW, POLYETHYLENE
machining wax
phenolic
plycarbonate, polysulone uitem 100
REN, Pattern/ modeling
wood
Hard wood
hard playwwod
mahogsny
MDF
soft plywood
soft wood
hard non- metals
fiber glass
graphite
ketron PEEK 1000
K Factor Hardness, Brinell
1.88 126
1.44 200
1.064 200-300
0.633 225-275
3.344 95
2.00 150

K Factor Hardness, Brinell

1.56 100-160
1.50 120
2.00 100-260
2.13 100-150
1.86 150-200
1.78 217
2.12 100-150
1.86 150-200
1.64 200-250
2.12 100-150
1.75 160-220
1.40
1.67 100-200
1.54
2.43 111
1.88 126
2.00 143
1.88 162
1.60 200
1.04 125-275
1.54 175-220
1.25 225-275
1.00 275-375
0.91 375-425
1.35 120-360
1.66 156
1.81 245
1.69 149
1.26 300
1.25 160-360
1.44 200
1.13 300
1.43 200
1.43 200
1.43 200
1.08 18-26Rc
1.14 24-32Rc
0.72 250-650
0.92 275-325
0.83 325-375
0.75 375-425
0.98 300
0.78 380-430
0.70 420-480
0.64 480-540
0.70 570-640
0.53 58-63 Rc
0.83 370
0.71 430-470
1.11 180-245
0.66 418-512
0.77 430
1.08 260
0.94 320
1.04 170-270
0.88 30-40Rc
1.33 175-225
1.33 187-220
1.14 170-360
1.29 190
1.26 215
1.33 160
1.22 235
1.14 240
1.60 200
1.22 185
1.13 300
1.11 310
1.07 340
1.13 300
1.11 270-360
1.14 260
1.09 217
0.93 300
1.06 200-300
0.87 336
1.14 200-250
1.14 200-250
0.88 330
1.14 225-255
0.77 >360
0.60 50-55Rc
0.60 50-55Rc
0.77 35-40Rc
0.65 40-45Rc
0.60 45-50Rc
0.58 50-55Rc
0.53 55-60Rc
0.50 60-65Rc
0.77 35-40
0.65 40-45
0.61 45-50
0.58 50-55
0.53 55-60
0.50 60-65
0.58 50-55Rc
0.45 60-65RC
0.78 40-45Rc
0.71 45-50Rc
0.64 50-55Rc
0.56 55-60Rc
0.83 275-325
0.77 360-420
0.71 410-475
1.33 200-275
1.30 200-250
1.25 225-275
1.25 225-275
0.77 360
0.90 36Rc
0.73 135-375
0.65 30-35Rc
1.00 135-185
1.00 135-185
1.00 187-235
1.00 200-285
0.86 200-285
1.00 170-185
1.44 135-325
0.56 381
0.63 280
0.66 270
1.75 150-200
0.59 275-325
0.63 225-275
0.69 185-220
0.63 225-275
0.68 225
0.62 285-300
0.63 255-275
0.67 235
0.63 255-275
0.63 30Rc
0.67 189-241
0.65 170-255
0.55 410
0.61 310-330
0.57 388
0.58 325-375
0.57 420
0.60 40rc
0.53 50rc
0.61 275-325
0.54 375-425
0.67 50-60
0.54 350-430
1.54 120-260
1.85 120-150
1.57 190-220
1.44 250-260
3.34 28-150
2.50 120
4.99 28
3.34 60
3.69 65
3.34 95
3.32 60-75
2.00 150
1.67
2.51
3.35 60-100
3.32 28-100
3.29 30-150
 3.34 28-150
9.07 65
3.99 100
2.01 50-250
1.73 95
1.65 150
3.01 60
1.19 225
2.55 80
2.14 105
2.55 65
1.38 190
2.00 42
3.33 60
1.20 120
1.67 80
0.77 180-390
0.77 340-390
0.91 260-280
1.14 180-255
0.91 275
0.78 260-280
0.69 300-336
0.91 100-450
1.75 159--183
0.96 285-311
0.83 321-352
0.80 356-394
0.71 395-450
1.78 108-124
0.97 270-305
0.63 200-300
0.55 189-241
0.65 170-255
0.99 200-450
0.39 345
0.49 207
0.63 180
0.63 180
0.46 238
0.62 180
0.42 277
0.41 300
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
10.00 1
1
 Blue = Input
Black = Output

Fusion 360 Rest Machining: Avoid Whisper Cuts

Initial CAM Operation

Radial Stock Surface Triangulation Contour Linearization

Tolerance to Leave Smoothing Tolerance Tolerance
0.0010 0.0050 0.0010 0.0004 0.0005
 Subsequent Operation

Max. Material Minimum Radial Stock

Left Tolerance to leave
0.0079 0.0010 0.011
Drilling 304 Stainless
Cobalt (NEEDS TO BE COBALT - not HSS!)
45 SFM
0.003 FPR
Full depth OR big pecks - e.g. 1x diameter
DeWalt CoBalt drills (lowes) are fine! (regular 135 degree, not of those started tips)

Carbide
75 SFM
0.003 FPR
Full depth OR big pecks - e.g. 1x diameter

135 angle drill

CARBIDE may break, cobalt is actually BETTER!
Center drill 0.030" deep; requires larger angle or the same (e.g. 140 degree center drill)
Make sure first peck isn't shallow!!!!

1/8" or smaller requires carbide.

Thin stainless (<0.1875") - your metal is twice as strong because the skin is on both sides. The thicker you go, the m
Oddly, sheet metal can be more challenging to drill than bar stock

1/4 Variable 5 Flute End Mill for Stainless Steel

http://www.lakeshorecarbide.com/14variable5fluteendmillforstainlesssteel.aspx
Use for outside profiling, clean up. DO NOT helical ramp
200 SFM
0.002 IPT
20% WOC
Max 0.25" DOC

1/4 Variable Flute End Mill for Steel

http://www.lakeshorecarbide.com/14variablefluteendmillforsteel.aspx
Use for Stainless Internal pockets and/or any helical ramping
225 SFM
0.001 IPT
10% WOC
Max 0.1875" DOC

From Patreon member:

Hey John, figured I throw you my 304l recipe on a haas.
M.A. Ford 5 flute 178 series 3/8" .020 corner radius. 10000rpm (982sfm) .0039 chip per tooth, 195.0ipm 25% stepov
Absolutely amazing tool life, and beautiful chip (blues/purples). .02" radial stock to leave for another 178 series to fin
Forgot to mention that formula is for using er32 collets to hold the windmills, could go faster with shrink fit holders
 ides. The thicker you go, the more easy (gummy) the center is.

er tooth, 195.0ipm 25% stepover (0.09375 WOC) .875 doc. 16 in3 min. Removal rate.
ave for another 178 series to finish.
faster with shrink fit holders
Roughing
SFM 4290
IPT 0.008
WOC 60%
DOC 0.35

Finish
SFM 3800
IPT 0.006
WOC 0.05
DOC 0.05

Ramp 7 degree and 0.004 IPT

Speeds & Feeds
SFM 1,950
Tool Diameter 0.500
IPT 0.01000
# Flutes 3
RPM 14,897
Feed (IPM) 446.9

Material Removal Rate & Horsepower Estimate

METRIC
IPM DOC WOC MRR (cu in) Material K Factor Est. Horsepower MM/Min DOC WOC MRR (cu cm)

268.0 0.50 0.100 13.40 6061-T6 Aluminum 3.34 4.01 6,807 12.7 2.54 220
357.0 0.50 0.125 22.31 6061-T6 Aluminum 3.34 6.67 9,068 12.7 3.175 366
447.0 0.50 0.125 27.94 6061-T6 Aluminum 3.34 8.35 11,354 12.7 3.175 458
447.0 0.50 0.200 44.70 6061-T6 Aluminum 3.34 13.37 11,354 12.7 5.08 733
Hole Diameter 0.31496
Radial Stock to Leave 0.00500
Effective Hole Diameter 0.30496

Tool Diameter 0.25000

Difference (Diameter) 0.06496
Difference (Radius) 0.03248

Max Stock To Leave 0.03000

Max. Helical Ramp Diameter 0.05000

https://forums.autodesk.com/autodesk/attachments/autodesk/276/468/1/millingTechInfoFormulas.pdf
http://www.practicalmachinist.com/vb/cnc-machining/calculating-hp-cut-177290/

DRILL HORSEPOWER CALCULATION

HP = (D / 4 * f * Vc * Kc) / (33,000 * Machine Efficiency)

D 0.5 Drill Diameter

f 0.01 Feed Per Revolution
Vc 300 Surface Feet per Minute
Kc 94,500 Specific Cutting Force (Lbf/Inch^2)
Force to cut a chip area of 1 mm² and thickness of 1 mm
Machine Efficiency 100%
HP 1.07
http://www.guhring.com/documents/Tech/Formulas/Drilling.pdf

Test Cuts!
Cut # SFM IPR HP RPM IPM Dia MRR
1 153 0.0046 0.25 1,175 5.5 0.5 1.06
2 153 0.010 0.56 1,175 11.75 0.5 2.31
3 200 0.010 0.73 1,527 15.27 0.5 3.00
4 250 0.010 0.91 1,909 19.1 0.5 3.75
5 300 0.010 1.10 2,291 22.9 0.5 4.50
6 300 0.012 1.32 2,291 27.5 0.5 5.40
7 400 0.01 1.46 3,050 31 0.5 5.99

MRR = (IPR * RPM) * pi * R^2

End Mill MRR

Formula: MRR = IPM * WOC * DOC

IPM
WOC 0.125
DOC 0.5
MRR 0

Convert Metric to Inch

Specific Cutting Force
lbs/in^2 94500 58000 348000
N/mm^2 650 400 2400
145.3846 145 145
Video Notes on Drilling
Goal of video: how hard can we push a drill, if/when it's a good tool, how much HP does it take!

Why drills?
Relatively cheap! McMaster 1/2" HSS only $8.72: 2896A43
Rake (face of tool) is designed to cut axially; flutes help pull chips up. Axially stiff. IOW: great for "plunging" (better
Great for pre-drilling into pockets to avoid slow/dangerous ramping with end mills OR you can use them to gang-dril
G-Wizard, LMS (http://littlemachineshop.com/reference/cuttingspeeds.php) or Machinery's Handbook

Drill Video
Cheap tool
High MRR
Less prone to chatter given machine strength, weight, wear, slop
Gang Drill!
Best way to remove materially axially
(Drill before you machine away to create tighter inside corner)

3 Minutes
Steel: low RPM's
Aluminum, brass, plastic, wood: high RPM's (but don't use spindle max)
NEED to make a chip!
As you rotate tool, needs to get underneath material to cut
20% WOC
50% DOC
0.001 to 0.003" IPT
foFormulas.pdf

fn 0.01
vc 300
dc 0.5
kc 87000

132000

0.988636

Kc Table Min Max Comments

Aluminum 58,000 94,500 Normal 6061 (~100 Brinnell hardness) is 94,500
Steel 216,500 291,500
W: great for "plunging" (better then end mills!)
you can use them to gang-drill pockets (think 2" deep pocket). AND I've even see folks gang-drill along a slot to avoid slotting
ery's Handbook
ot to avoid slotting