End Milling Horsepower Calculations

For Indexable Insert End Mill with KM Quick-Change Tooling


! These calculations are based upon theoretical values and are only intended for planning purposes; not precise projections of cutting forces. Actual results will vary. No responsibility from Kennametal is assumed.

Conversion of Workpiece Material Rockwell (Optional)

Hardness HRB OR HRC into Brinell Hardness (HB)

Skip this step if you already know the Brinell hardness number(HB)
     :     

Characteristics of Workpiece Materials

    Brinell Hardness:     HB
    Ultimate strength:     psi

End Mill Nomenclature

D1     Effective cutting diameter:        in.
dKM     Input KM size:  
l1     Distance from the centerline to the nose radius of the insert:     in.
l2     Distance from the flange face to the nose radius of the insert:     in.
z     Number of inserts:  

Machining Conditions

Vc     Cutting speed:     SFM
ap     Axial depth of cut:     in. DOC
ae     Radial width of cut:     in. WOC
fz     Feed per tooth:     IPT (chip load)
    Machinability factor:      
    Tool wear factor:      
E     Machine efficiency factor:         

  

Safe Operating Conditions

CL     Empirical coefficient for load:     
Fmax     Mamimum permissible load applied to KM joint:     lb
Ftmax     Maximum permissible tangential force:     lb
CT     Empirical coefficient for torque:     
Tmax     Maximum permissible torque applied to KM joint:     ft lb
Tp     Maximum permissible actual torque:     ft lb

Calculated Machining Conditions

n     Spindle speed:     RPM
Vf     Feed rate:     IPM  (no productivity formula)
    Reduced feed per tooth:     in.  (chip load at the cut)
Fp     Feed rate:     IPM  (with productivity formula)
Q     Metal removal rate:     in3 / min    MRR

A     Cross-sectional area of the chip:     in.2
    Number of inserts in the cut:  
    Ratio of radial width of cut to cutting diameter:  

Calculated Force, Torque, and Required Power

Ft     Actual tangential force:     lbf     should not exceed Ft max
T     Actual torque:     ft-lb   should not exceed Tp

    Machining power  
        at the cutter:     HPc
        at the motor:   hp