Ball nose Hard Milling Cusp Height

Step over
To find Step over amount to get Cusp Height

Enter Tool Diameter 0.2500 6.3500

Enter Cusp Height 0.0005 0.0127

Depth of Cut

Answer Amount of Step over needed

0.02234 0.5674

Cusp Height
Step Over
Ball nose Hard Milling
To find Cusp Height

Enter Tool Diameter 0.2500 6.3500

Depth of Cut

Enter Step Over 0.0150 0.3810

Answer Cusp Height

0.00023 0.0057
 Depth of Cut

Ball nose Hard Milling

Tool Diameter

To find Effective Cutting Diameter

Enter Tool Diameter 0.2500 6.3500

Enter Depth of Cut 0.0100 0.2540
Effective Tool Diameter
Answer Effective CuttingDiameter
0.09798 2.4887 In Put MM Inch

15 0.5906

Ball nose Hard Milling

To find Effective Chip Load
In Put MM Inch

Enter Center line chip Load 0.0025 0.0635 15 0.5906

Tool Diameter Depth of Cut

Enter Number of Flutes 2
Enter Step Over 0.0300 0.7620

Enter Tool Diameter 0.5000 12.7000

Step Over

Enter Depth of Cut 0.0100 0.2540

Effective Tool Diameter
Answer Effective CuttingDiameter
Chip Load Step Over 0.00087 0.022
0.14000 3.5560 Chip Load Depth 0.00050 0.0127
The following is based on the chip load
and effective cutting diameter from above information

Enter SFM from Chart 200.00 60.9600 RPM IS 5457

IPM (feed) mm meter
RPM based on Effective Cutting Diameter IPM IS 27.29 27.29 693.0585 0.6931

Rules Based on above Information

For Step over = Cusp Height needed
inch mm
For Depth of cut 0.5000 12.7000254

Percent of Radius For depth of cut Steel < 40 RC Reccomended Depth of cut
80% Depth on Roughing 0.2000 5.0800
27% Depth on Finishing 0.0675 1.7145

Steel < 50 RC
24% Depth on Roughing 0.0600 1.5240
8% Depth on Finishing 0.0200 0.5080
Steel < 60 RC
15% Depth on Roughing 0.0375 0.9525
5% Depth on Finishing 0.0125 0.3175
Ball Nose Chart
Center Line Chip Loads and SFM by RC Hardness
SFM SFM
970.00 675.00

Steel< 40 RC Steel< 50 RC
Tool Diameter dec eq chip load chip load
1/32 0.0312 0.0006 0.0004
3/64 0.0468 0.0009 0.0006
1/16 0.0625 0.0012 0.0008
5/64 0.0781 0.0015 0.0011
3/32 0.0937 0.0018 0.0013
7/64 0.1093 0.0021 0.0015
1/8 0.125 0.0024 0.0017
9/64 0.1406 0.0028 0.0019
5/32 0.1562 0.0031 0.0021
11/64 0.1718 0.0034 0.0023
3/16 0.1875 0.0037 0.0025
13/64 0.2031 0.0040 0.0027
7/32 0.2187 0.0043 0.0030
15/64 0.2343 0.0046 0.0032
1/4 0.25 0.0049 0.0034
17/64 0.2656 0.0052 0.0036
9/32 0.2812 0.0055 0.0038
19/64 0.2968 0.0058 0.0040
5/16 0.3125 0.0061 0.0042
21/64 0.3281 0.0064 0.0044
11/32 0.3437 0.0067 0.0046
23/64 0.3593 0.0070 0.0049
3/8 0.375 0.0073 0.0051
25/64 0.3906 0.0076 0.0053
13/32 0.4062 0.0080 0.0055
27/64 0.4218 0.0083 0.0057
7/16 0.4375 0.0086 0.0059
29/64 0.4531 0.0089 0.0061
15/32 0.4687 0.0092 0.0063
31/64 0.4843 0.0095 0.0065
1/2 0.5 0.0098 0.0068
9/16 0.5625 0.0110 0.0076
5/8 0.625 0.0122 0.0084
3/4 0.75 0.0147 0.0101
7/8 0.875 0.0171 0.0118
1 1 0.0196 0.0135
by RC Hardness
SFM
500.00

Steel< 60 RC
chip load
0.0003
0.0005
0.0006
0.0008
0.0009
0.0011
0.0013
0.0014
0.0016
0.0017
0.0019
0.0020
0.0022
0.0023
0.0025
0.0027
0.0028
0.0030
0.0031
0.0033
0.0034
0.0036
0.0038
0.0039
0.0041
0.0042
0.0044
0.0045
0.0047
0.0048
0.0050
0.0056
0.0063
0.0075
0.0088
0.0100
 End Mill
Speed and Feed Calculation
For Slotting
Based on the above information
Input Information from the Yellow Cells above C
Cutter Dia.
A 0.4720 11.989 A
Depth of Cut
Chart Below 0.0250 0.635 End Mill
Width =Cutter Diameter
C 0.4720 11.988824
SFM

From Material Chart 130 39.62 Answer

# Teeth on End Mill RPM
4 1052
Feed per Tooth (FPT) Adj. FPT IPM (feed)
From End Mill Spec
Chart 0.0009 0.0009 4
0.023 0.023
When slotting RPM is reduced, chip load will be the same.

Rules Based on above Information

For Step over = Cusp Height need

For Radial Depth o

Percent of Radial depth of cut of Diameter
40%

Steel 45 to 50
25%

Steel 50 to 55
20%

Steel 55 to 60
15%

Steel 60 to 65
10%
 RPM

C
IPM In Put MM Inch
15 0.5906

B Chart Below

Cu. Inches/Min. Removed IPM (feed) mm meter

0.045 4 96.2059 0.0962

hip load will be the same.

nformation
ver = Cusp Height needed

For Radial Depth of cut

Steel < 45 RC Reccomended Depth of cut
 Radial on Roughing 0.0944 2.3978

Steel 45 to 50 RC
Radial on Roughing 0.0590 1.4986

Steel 50 to 55 RC
Radial on Roughing 0.0472 1.1989

Steel 55 to 60 RC
Radial on Roughing 0.0354 0.8992
Steel 60 to 65 RC
Radial on Roughing 0.0236 0.5994
End Mill Chart Slotting Roughing
Center Line Chip Loads and SFM by RC Hardness
SFM SFM SFM
120 105 90
240 210 180
Steel< 45 RC Steel 45 to 50 RC Steel 50 to 55 RC
Tool Diamete dec eq mm chip load chip load chip load
1/32 0.0312 0.7925 0.00015 0.00013 0.00008
3/64 0.0468 1.1887 0.00023 0.00019 0.00013
1/16 0.0625 1.5875 0.00031 0.00025 0.00017
5/64 0.0781 1.9837 0.00038 0.00032 0.00021
3/32 0.0937 2.3800 0.00046 0.00038 0.00025
7/64 0.1093 2.7762 0.00053 0.00044 0.00030
1/8 0.125 3.1750 0.00061 0.00051 0.00034
9/64 0.1406 3.5712 0.00069 0.00057 0.00038
5/32 0.1562 3.9675 0.00076 0.00063 0.00042
11/64 0.1718 4.3637 0.00084 0.00070 0.00046
3/16 0.1875 4.7625 0.00092 0.00076 0.00051
13/64 0.2031 5.1588 0.00099 0.00082 0.00055
7/32 0.2187 5.5550 0.00107 0.00089 0.00059
15/64 0.2343 5.9512 0.00115 0.00095 0.00063
1/4 0.25 6.3500 0.0012 0.0010 0.0007
17/64 0.2656 6.7463 0.0013 0.0011 0.0007
9/32 0.2812 7.1425 0.0014 0.0011 0.0008
19/64 0.2968 7.5387 0.0015 0.0012 0.0008
5/16 0.3125 7.9375 0.0015 0.0013 0.0008
21/64 0.3281 8.3338 0.0016 0.0013 0.0009
11/32 0.3437 8.7300 0.0017 0.0014 0.0009
23/64 0.3593 9.1262 0.0018 0.0015 0.0010
3/8 0.375 9.5250 0.0018 0.0015 0.0010
25/64 0.3906 9.9213 0.0019 0.0016 0.0011
13/32 0.4062 10.3175 0.0020 0.0016 0.0011
27/64 0.4218 10.7137 0.0021 0.0017 0.0011
7/16 0.4375 11.1125 0.0021 0.0018 0.0012
29/64 0.4531 11.5088 0.0022 0.0018 0.0012
15/32 0.4687 11.9050 0.0023 0.0019 0.0013
31/64 0.4843 12.3012 0.0024 0.0020 0.0013
1/2 0.5 12.7000 0.0024 0.0020 0.0014
9/16 0.5625 14.2875 0.0028 0.0023 0.0015
5/8 0.625 15.8750 0.0031 0.0025 0.0017
3/4 0.75 19.0500 0.0037 0.0030 0.0020
7/8 0.875 22.2250 0.0043 0.0035 0.0024
1 1 25.4001 0.0049 0.0041 0.0027
 SFM SFM
80 65
160 130
Steel 55 to 60 RC Steel 60 to 65 RC
chip load chip load
0.00007 0.00005
0.00011 0.00008
0.00015 0.00011
0.00019 0.00014
0.00022 0.00016
0.00026 0.00019
0.00030 0.00022
0.00034 0.00025
0.00037 0.00027
0.00041 0.00030
0.00045 0.00033
0.00049 0.00036
0.00052 0.00038
0.00056 0.00041
0.0006 0.0004
0.0006 0.0005
0.0007 0.0005
0.0007 0.0005
0.0008 0.0005
0.0008 0.0006
0.0008 0.0006
0.0009 0.0006
0.0009 0.0007
0.0009 0.0007
0.0010 0.0007
0.0010 0.0007
0.0011 0.0008
0.0011 0.0008
0.0011 0.0008
0.0012 0.0008
0.0012 0.0009
0.0014 0.0010
0.0015 0.0011
0.0018 0.0013
0.0021 0.0015
0.0024 0.0018
 Speed and Feed Calculation
For Peripheral Milling
Input Selection into Yellow Cells
Cutter Dia.
A 0.5000 12.700 A
Depth of Cut
B 0.2500 6.350 End Mill
Radial Depth of Cut
Chart Below 0.1000 2.540005
SFM m/min
From Material
Chart 250 76.20 Answer
# Teeth on End Mill RPM
4 1910
Feed per Tooth (FPT) Adj. FPT IPM (feed)
From End Mill
Spec Chart 0.0025 0.0016 19

0.064 0.040
Percent of Radial depth of cut of Diameter For Radial Depth of
2 x Diameter Depth of cut
10%

1.5 x Diameter Depth of cut Steel 45 to 50 R

7%

1.5 x Diameter Depth of cut Steel 50 to 55 R

5%
1.25 x Diameter Depth of cut Steel 55 to 60 R
3%

1 x Diameter Depth of cut Steel 60 to 65 R

2%
 C In Put MM Inch
15 0.5906
RPM

IPM
B
Radial Depth of Cut "C"
Chart Below

Cu. Inches/Min. Removed IPM (feed) mm meter

19 485.1410 0.4851

For Radial Depth of cut Reccomended

Steel < 45 RC Radial Depth of cut
Radial on Roughing 0.0250 0.6350

Steel 45 to 50 RC
Radial on Roughing 0.0175 0.4445

Steel 50 to 55 RC
Radial on Roughing 0.0125 0.3175
Steel 55 to 60 RC
Radial on Roughing 0.0075 0.1905

Steel 60 to 65 RC
Radial on Roughing 0.0050 0.1270
End Mill Chart Peripheral Roughing
Center Line Chip Loads and SFM by RC Hardness
SFM SFM SFM
120 105 90
240 210 180
Steel< 45 RC Steel 45 to 50 RC Steel 50 to 55 RC
Tool Diamete dec eq mm chip load chip load chip load
1/32 0.0312 0.7925 0.00031 0.00021 0.00014
3/64 0.0468 1.1887 0.00046 0.00032 0.00021
1/16 0.0625 1.5875 0.00061 0.00042 0.00028
5/64 0.0781 1.9837 0.00076 0.00053 0.00035
3/32 0.0937 2.3800 0.00092 0.00063 0.00042
7/64 0.1093 2.7762 0.00107 0.00074 0.00049
1/8 0.125 3.1750 0.00122 0.00084 0.00056
9/64 0.1406 3.5712 0.00138 0.00095 0.00063
5/32 0.1562 3.9675 0.00153 0.00105 0.00070
11/64 0.1718 4.3637 0.00168 0.00116 0.00077
3/16 0.1875 4.7625 0.00184 0.00127 0.00084
13/64 0.2031 5.1588 0.0020 0.0014 0.0009
7/32 0.2187 5.5550 0.0021 0.0015 0.0010
15/64 0.2343 5.9512 0.0023 0.0016 0.0011
1/4 0.25 6.3500 0.0024 0.0017 0.0011
17/64 0.2656 6.7463 0.0026 0.0018 0.0012
9/32 0.2812 7.1425 0.0028 0.0019 0.0013
19/64 0.2968 7.5387 0.0029 0.0020 0.0013
5/16 0.3125 7.9375 0.0031 0.0021 0.0014
21/64 0.3281 8.3338 0.0032 0.0022 0.0015
11/32 0.3437 8.7300 0.0034 0.0023 0.0015
23/64 0.3593 9.1262 0.0035 0.0024 0.0016
3/8 0.375 9.5250 0.0037 0.0025 0.0017
25/64 0.3906 9.9213 0.0038 0.0026 0.0018
13/32 0.4062 10.3175 0.0040 0.0027 0.0018
27/64 0.4218 10.7137 0.0041 0.0028 0.0019
7/16 0.4375 11.1125 0.0043 0.0030 0.0020
29/64 0.4531 11.5088 0.0044 0.0031 0.0020
15/32 0.4687 11.9050 0.0046 0.0032 0.0021
31/64 0.4843 12.3012 0.0047 0.0033 0.0022
1/2 0.5 12.7000 0.0049 0.0034 0.0023
9/16 0.5625 14.2875 0.0055 0.0038 0.0025
5/8 0.625 15.8750 0.0061 0.0042 0.0028
3/4 0.75 19.0500 0.0073 0.0051 0.0034
7/8 0.875 22.2250 0.0086 0.0059 0.0039
1 1 25.4001 0.0098 0.0068 0.0045
 SFM SFM
80 65
160 130
Steel 55 to 6 Steel 60 to 65 RC
chip load chip load
0.00012 0.00011
0.00019 0.00016
0.00025 0.00022
0.00031 0.00027
0.00037 0.00033
0.00044 0.00038
0.00050 0.00044
0.00056 0.00049
0.00062 0.00055
0.00069 0.00060
0.00075 0.00066
0.0008 0.0007
0.0009 0.0008
0.0009 0.0008
0.0010 0.0009
0.0011 0.0009
0.0011 0.0010
0.0012 0.0010
0.0013 0.0011
0.0013 0.0011
0.0014 0.0012
0.0014 0.0013
0.0015 0.0013
0.0016 0.0014
0.0016 0.0014
0.0017 0.0015
0.0018 0.0015
0.0018 0.0016
0.0019 0.0016
0.0019 0.0017
0.0020 0.0018
0.0023 0.0020
0.0025 0.0022
0.0030 0.0026
0.0035 0.0031
0.0040 0.0035
 Speed and Feed Calculation
For Peripheral Milling
Input Selection into Yellow Cells
Cutter Dia.
A 0.2340 5.944 A
Depth of Cut
B 0.2000 5.080 End Mill
Radial Depth of Cut
Chart Below 0.0020 0.0508
SFM m/min
From Material
Chart 600 182.88 Answer
# Teeth on End Mill RPM
8 9795
Feed per Tooth (FPT) Adj. FPT IPM (feed)
From End Mill
Spec Chart 0.0016 0.0002 125

0.041 0.005
Percent of Radial depth of cut of Diameter For Radial Depth of
2 x Diameter Depth of cut
10%

1.5 x Diameter Depth of cut Steel 45 to 50 R

5%

1.5 x Diameter Depth of cut Steel 50 to 55 R

5%
1.25 x Diameter Depth of cut Steel 55 to 60 R
3%

1 x Diameter Depth of cut Steel 60 to 65 R

2%
 C
In Put MM Inch
RPM
15 0.5906

IPM
B
Radial Depth of Cut "C"
Chart Below

Cu. Inches/Min. Removed IPM (feed) mm meter

125 3184.5151 3.1845

For Radial Depth of cut Reccomended

Steel < 45 RC Radial Depth of cut
Radial on Roughing 0.0117 0.2972

Steel 45 to 50 RC
Radial on Roughing 0.0059 0.1486

Steel 50 to 55 RC
Radial on Roughing 0.0059 0.1486
Steel 55 to 60 RC
Radial on Roughing 0.0035 0.0892

Steel 60 to 65 RC
Radial on Roughing 0.0023 0.0594
End Mill Chart Peripheral Finishing
Center Line Chip Loads and SFM by RC Hardness
SFM SFM SFM
600.00 500.00 450.00
Steel< 45 RC Steel 45 to 50 Steel 50 to 55 RC
Tool Diameter dec eq chip load chip load chip load
1/32 0.0312 0.00031 0.00021 0.00014
3/64 0.0468 0.00046 0.00032 0.00021
1/16 0.0625 0.00061 0.00042 0.00028
5/64 0.0781 0.00076 0.00053 0.00035
3/32 0.0937 0.00092 0.00063 0.00042
7/64 0.1093 0.00107 0.00074 0.00049
1/8 0.125 0.00122 0.00084 0.00056
9/64 0.1406 0.00138 0.00095 0.00063
5/32 0.1562 0.00153 0.00105 0.00070
11/64 0.1718 0.00168 0.00116 0.00077
3/16 0.1875 0.00184 0.00127 0.00084
13/64 0.2031 0.00199 0.00137 0.00091
7/32 0.2187 0.00214 0.00148 0.00098
15/64 0.2343 0.00229 0.00158 0.00105
1/4 0.25 0.00245 0.00169 0.00113
17/64 0.2656 0.00260 0.00179 0.00120
9/32 0.2812 0.00275 0.00190 0.00127
19/64 0.2968 0.00290 0.00200 0.00134
5/16 0.3125 0.00306 0.00211 0.00141
21/64 0.3281 0.00321 0.00221 0.00148
11/32 0.3437 0.00336 0.00232 0.00155
23/64 0.3593 0.00352 0.00243 0.00162
3/8 0.375 0.00367 0.00253 0.00169
25/64 0.3906 0.00382 0.00264 0.00176
13/32 0.4062 0.00398 0.00274 0.00183
27/64 0.4218 0.00413 0.00285 0.00190
7/16 0.4375 0.00428 0.00295 0.00197
29/64 0.4531 0.00443 0.00306 0.00204
15/32 0.4687 0.00459 0.00316 0.00211
31/64 0.4843 0.0047 0.0033 0.0022
1/2 0.5 0.0049 0.0034 0.0023
9/16 0.5625 0.0055 0.0038 0.0025
5/8 0.625 0.0061 0.0042 0.0028
3/4 0.75 0.0073 0.0051 0.0034
7/8 0.875 0.0086 0.0059 0.0039
1 1 0.0098 0.0068 0.0045
 SFM SFM
350.00 275.00
Steel 55 to 60 RC Steel 60 to 65 RC
chip load chip load
0.00012 0.00011
0.00019 0.00016
0.00025 0.00022
0.00031 0.00027
0.00037 0.00033
0.00044 0.00038
0.00050 0.00044
0.00056 0.00049
0.00062 0.00055
0.00069 0.00060
0.00075 0.00066
0.00081 0.00071
0.00087 0.00077
0.00094 0.00082
0.00100 0.00088
0.00106 0.00093
0.00112 0.00098
0.00119 0.00104
0.00125 0.00109
0.00131 0.00115
0.00137 0.00120
0.00144 0.00126
0.00150 0.00131
0.00156 0.00137
0.00162 0.00142
0.00169 0.00148
0.00175 0.00153
0.00181 0.00159
0.00187 0.00164
0.0019 0.0017
0.0020 0.0018
0.0023 0.0020
0.0025 0.0022
0.0030 0.0026
0.0035 0.0031
0.0040 0.0035