Face Milling Horsepower Calculations

For Kennametal Face Milling Applications with High Shear Cutters


! 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

Face Mill Nomenclature

d1     Effective cutting diameter:     in
z     Number of inserts in the cutter:  

Machining Conditions

Vc     Cutting speed:     (SFM)
ap     Axial depth of cut:     in. (DOC)
ae     Radial width of cut:     in. (WOC)
fz     Required feed per tooth:     in. (IPT) (chip load)
Cm     Radial engagement factor:      
E     Machine efficiency factor:         

  

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)
Qp     Metal removal rate:     (MRR)  (no productivity formula)
Q     Metal removal rate:     (MRR)  (with productivity formula)

A     Cross-sectional area of the chip:     in.2
zc     Number of inserts in the cut:  
ae/d1     Ratio of radial width of cut to cutting diameter:  

Calculated Force, Torque, and Required Power

Ft     Tangential cutting force:     lb
T     Torque at the cutter:     in.-lb      ft-lb

    Machining power  
Ps         at the cutter:     (HPc)
Pm         at the motor:   hp