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	<title>The CNC Project</title>
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		<title>The CNC Project</title>
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		<title>How to Determine SFM for an Operation</title>
		<link>http://cnctips.wordpress.com/2012/02/08/how-to-determine-sfm/</link>
		<comments>http://cnctips.wordpress.com/2012/02/08/how-to-determine-sfm/#comments</comments>
		<pubDate>Wed, 08 Feb 2012 18:07:21 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[Feeds and Speeds]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>
		<category><![CDATA[Manual Data Input]]></category>
		<category><![CDATA[MDI]]></category>
		<category><![CDATA[CNC]]></category>
		<category><![CDATA[Cutting Speed]]></category>
		<category><![CDATA[cutting tools]]></category>
		<category><![CDATA[feed rate]]></category>
		<category><![CDATA[feedrate]]></category>

		<guid isPermaLink="false">http://cnctips.wordpress.com/?p=534</guid>
		<description><![CDATA[ Henry wrote and asked a good question:  &#8221;How do you determine the correct SFM for machining a part?&#8221; Good question Henery. Choosing the correct SFM really depends a number of things. Machinability of the material (see http://www.carbidedepot.com/formulas-machinability.htm ) The tool material (carbide, High Speed Steel, Ceramic, etc) The rigidity of the set up And so [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=534&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><span style="color:#003366;"> Henry wrote and asked a good question: </span></p>
<h4><span style="color:#003366;"> &#8221;How do you determine the correct SFM for machining a part?&#8221; </span></h4>
<p><span style="color:#003366;">Good question Henery. Choosing the correct SFM really depends a number of things.</span></p>
<ol>
<li><span style="color:#003366;">Machinability of the material (see <a href="http://www.carbidedepot.com/formulas-machinability.htm"><span style="color:#003366;">http://www.carbidedepot.com/formulas-machinability.htm</span></a> )</span></li>
<li><span style="color:#003366;">The tool material (carbide, High Speed Steel, Ceramic, etc)</span></li>
<li><span style="color:#003366;">The rigidity of the set up</span></li>
</ol>
<p><span style="color:#003366;">And so on.</span></p>
<p><span style="color:#003366;">Once you know the material characteristics and tool material you can go to <a title="Machinery's Handbook" href="http://www.amazon.com/dp/0831127007?tag=haydenpubcom-20&amp;camp=14573&amp;creative=327641&amp;linkCode=as1&amp;creativeASIN=0831127007&amp;adid=0W542GPHYW9V9RBEZ0FQ&amp;&amp;ref-refURL=http%3A%2F%2Fhaydenpub.com%2Fmachining.html" target="_blank"><span style="color:#003366;">machinery&#8217;s handabook</span></a> or <a title="Machining books" href="http://haydenpub.com/machining.html" target="_blank"><span style="color:#003366;">similar texts </span></a>and look up speeds and feeds for optimum conditions for various operations like drilling, milling, threading, turning and so on.</span></p>
<p><span style="color:#003366;">Another great source of information for speeds and feeds is provided by the carbide manufacturers like <span style="color:#ff0000;"><a title="Kennametal Resources" href="http://www.kennametal.com/en-US/products_services/metalworking_main_products_services.jhtml" target="_blank"><span style="color:#ff0000;">Kennametal</span></a></span>, <a title="Valenite / Walter cutting tools" href="http://ww2.walter-ag.de:8080/sap/bc/gui/sap/its/ZZWALTEROSTORE/?sap-language=EN&amp;ostore%5B1%5D=WBAU1_E&amp;~okcode%5B1%5D=TOL&amp;~target%5B1%5D=_top&amp;~forcetarget%5B1%5D=yes" target="_blank"><span style="color:#003366;"><span style="color:#ff0000;">Valenite</span> <span style="color:#ff0000;">(now Walter</span>), </span></a> <span style="color:#ff0000;"><a title="SECO tools" href="http://www.secotools.com/en-US/Global/Products/" target="_blank"><span style="color:#ff0000;">Seco Tools </span></a></span>and <span style="color:#ff0000;"><a title="Iscar cutting tools" href="http://www.iscar.com/" target="_blank"><span style="color:#ff0000;">Iscar</span></a></span>, to name a few.   These companies have catalogs and websites containing a wealth of information about speeds and feeds for their cutting tools.   And, if you are a customer they generally have application engineers available to assist you.</span></p>
<p><span style="color:#003366;">All machining conditions are different, so basically you start with the redommended Speeds and Feeds (assuming you have adequate rigidity for safe maching) and tweak the process from there depending on your needs for productivity, tool life, repeatability, machine capability etc.</span></p>
<p><span style="color:#003366;">Great question Henry, thanks for asking.  I hope this information helps you.</span></p>
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			<media:title type="html">Dave</media:title>
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		<title>Sorry, 7 Easy Steps to CNC Sold out again</title>
		<link>http://cnctips.wordpress.com/2012/01/25/sorry-7-easy-steps-to-cnc-sold-out-again/</link>
		<comments>http://cnctips.wordpress.com/2012/01/25/sorry-7-easy-steps-to-cnc-sold-out-again/#comments</comments>
		<pubDate>Wed, 25 Jan 2012 18:47:23 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>

		<guid isPermaLink="false">http://cnctips.wordpress.com/?p=530</guid>
		<description><![CDATA[Haydenpub.com has once again sold out of all printed copies of their best selling 7 Easy Steps to CNC and 7 Easy Steps to BobCAD books.    Thanks for all the great business and remember to post your comments and questions, I will answer them as soon as I get the time. This ragged economy seems [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=530&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><span style="color:#000080;font-size:large;"><span style="font-size:large;">Haydenpub.com has once again sold out of all printed copies of their best selling<br />
7 Easy Steps to CNC and 7 Easy Steps to BobCAD books.    Thanks for all the great business and remember to post your comments and questions, I will answer them as soon as I get the time.</span></span></p>
<p><span style="color:#000080;font-size:large;"><span style="font-size:large;">This ragged economy seems to be driving people to want to learn more about CNC programming.  Hopefully, more people will start entering the machining trades.  It is a great profession, challenging, pay fairly well and easy to get into if you have mechanical abilities and a drive to learn. </span></span></p>
<p><span style="color:#000080;font-size:large;"><span style="font-size:large;">At the rate CNC machinists and programmers are retiring, this is a great career to jump into.</span></span></p>
<div align="center"><span style="color:#ff0000;font-size:large;"><strong>PRINTED Inventory SOLD OUT for January<br />
only printable until FEB 7 2012<br />
<a href="http://www.cncmcodes.com/page/444653772" target="_self"><strong><span style="font-size:large;">CLICK HERE for available (printable) E books</span></strong></a><strong><span style="font-size:large;"></p>
<p></span></strong></strong></span></div>
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			<media:title type="html">Dave</media:title>
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		<title>$7 CNC books (shameless self-promotion)</title>
		<link>http://cnctips.wordpress.com/2012/01/05/7-dollar-cnc-books/</link>
		<comments>http://cnctips.wordpress.com/2012/01/05/7-dollar-cnc-books/#comments</comments>
		<pubDate>Thu, 05 Jan 2012 18:43:36 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>
		<category><![CDATA[Supervisor tips]]></category>
		<category><![CDATA[Uncategorized]]></category>

		<guid isPermaLink="false">http://cnctips.wordpress.com/?p=522</guid>
		<description><![CDATA[7 Easy Steps To CNC Programming and 7 Easy Steps to BobCAD Ebook Promotion Due to the outstanding number of hits we received on this blog, it&#8217;s time to make an offer (shameless self promotion) to our loyal followers. We have a new website and because of its success and the success of this blog, [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=522&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<h2>7 Easy Steps To CNC Programming and 7 Easy Steps to BobCAD Ebook Promotion</h2>
<p>Due to the outstanding number of hits we received on this blog, it&#8217;s time to make an offer (shameless self promotion) to our loyal followers.</p>
<p>We have a new website and because of its success and the success of this blog, we have lowered the price on all of our Ebooks to only $7.00 and we have made printable so you can print a copy to take to work or keep by your machine.</p>
<p>To take advantage of this offer.<br />
Go to <a title="Hayden Publishing $7 E Books" href="http://www.cncmcodes.com/page/444653772" target="_blank">http://www.cncmcodes.com/page/444653772</a> and follow these easy steps (Y<em>ou will know what to do.  These instructions are listed because different browesers and settings will sometimes skip the download page</em>)</p>
<h2>$7 CNC E book download instructions</h2>
<ol>
<li>Find the book(s) you want and click on More Info.</li>
<li>Click on add to cart (at the bottom of the page).</li>
<li>Either contuinue shopping or Checkout.</li>
<li>process payment.</li>
<li>If you don&#8217;t get transferred to the download page, click on the <a title="Order Tracking Button for CNC ebooks" href="http://www.cncmcodes.com/tracking" target="_blank">Track Your Order </a>tab at the top of the page.</li>
<li>Enter your order number in the field provided and press VIEW</li>
<li>Your Downloadable books will be listed at the bottom of the PAGE as <strong><span style="color:#303092;">BLUE</span></strong> links</li>
</ol>
<h2>To post questions for this Blog</h2>
<ul>
<li>Either respond to any posting on this blog or</li>
<li>go to <a href="http://www.cncmcodes.com/http://cncmcodes.com/page/cnc-tips-blog">http://www.cncmcodes.com/http://cncmcodes.com/page/cnc-tips-blog</a> and post your question</li>
</ul>
<p>Thanks for making this a great year for this CNC Tips Blog and for Haydenpub.com / CNCMCODES.com</p>
<p>David Hayden</p>
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			<media:title type="html">Dave</media:title>
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		<title>2011 in review</title>
		<link>http://cnctips.wordpress.com/2012/01/01/2011-in-review/</link>
		<comments>http://cnctips.wordpress.com/2012/01/01/2011-in-review/#comments</comments>
		<pubDate>Mon, 02 Jan 2012 03:48:09 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[Uncategorized]]></category>

		<guid isPermaLink="false">http://cnctips.wordpress.com/?p=518</guid>
		<description><![CDATA[The WordPress.com stats helper monkeys prepared a 2011 annual report for this blog. Here&#8217;s an excerpt: The concert hall at the Syndey Opera House holds 2,700 people. This blog was viewed about 20,000 times in 2011. If it were a concert at Sydney Opera House, it would take about 7 sold-out performances for that many [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=518&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p>The WordPress.com stats helper monkeys prepared a 2011 annual report for this blog.</p>
<p>	<a href="/2011/annual-report/"><img src="http://www.wordpress.com/wp-content/mu-plugins/annual-reports/img/emailteaser.jpg" width="100%" alt="" /></a></p>
<p>Here&#8217;s an excerpt:</p>
</p>
<blockquote><p>The concert hall at the Syndey Opera House holds 2,700 people.  This blog was viewed about <strong>20,000</strong> times in 2011.  If it were a concert at Sydney Opera House, it would take about 7 sold-out performances for that many people to see it.</p></blockquote>
<p><a href="/2011/annual-report/">Click here to see the complete report.</a></p>
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		<title>The Women of CNC</title>
		<link>http://cnctips.wordpress.com/2011/09/14/the-women-of-cnc/</link>
		<comments>http://cnctips.wordpress.com/2011/09/14/the-women-of-cnc/#comments</comments>
		<pubDate>Wed, 14 Sep 2011 17:43:03 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>
		<category><![CDATA[Supervision]]></category>
		<category><![CDATA[supervisor]]></category>
		<category><![CDATA[Uncategorized]]></category>
		<category><![CDATA[CNC Jobs]]></category>
		<category><![CDATA[CNC Machinist]]></category>
		<category><![CDATA[CNC Operator]]></category>
		<category><![CDATA[CNC Supervisor]]></category>
		<category><![CDATA[CNC Women]]></category>
		<category><![CDATA[Employment]]></category>
		<category><![CDATA[management]]></category>
		<category><![CDATA[Production Management]]></category>
		<category><![CDATA[Women Machinists]]></category>

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		<description><![CDATA[I am working on a new article and am looking for success stories about the success of women as CNC machinists, operators, programmers, supervisors.<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=504&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p>I am working on a new article and am looking for success stories about the success of women  as CNC machinists, operators, programmers, supervisors.</p>
<p>If you have a good story or comments on the subject, comment on this post- I will review for content and if applicable use anecdotally within the article.</p>
<p>Suitable posts will be approved for posting on this blog &#8220;as is.&#8221;</p>
<p>Of interest are things like:</p>
<ol>
<li>How did you get into the trade</li>
<li>do you like it</li>
<li>Do you feel your pay and treatment are consistent with male colleagues</li>
<li>would you recommend the trade to other women</li>
<li>what were your barriers to entering the business of CNC</li>
<li>what training do you feel women should seek to succeed</li>
<li>success stories (what did you overcome, achieve, etc)</li>
</ol>
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			<media:title type="html">Dave</media:title>
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		<title>CNC Programming and Tool Nose Radius</title>
		<link>http://cnctips.wordpress.com/2011/09/02/cnc-programming-and-tool-nose-radius/</link>
		<comments>http://cnctips.wordpress.com/2011/09/02/cnc-programming-and-tool-nose-radius/#comments</comments>
		<pubDate>Fri, 02 Sep 2011 17:21:17 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>
		<category><![CDATA[Manual Data Input]]></category>
		<category><![CDATA[MDI]]></category>
		<category><![CDATA[Positioning]]></category>
		<category><![CDATA[CNC Machinist]]></category>
		<category><![CDATA[CNC Operator]]></category>

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		<description><![CDATA[To be a good NC/CNC programmer you must understand how the radius of a tool affects your programming points.  The radius may be on the end of a lathe tool or the radius of a milling cutter.
<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=495&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><span style="color:#000080;">To be a good NC/CNC programmer you must understand how the radius of a tool affects your programming points.  The radius may be on the end of a lathe tool or the radius of a milling cutter.</span></p>
<p><span style="color:#000080;">The following is excerpted from the FAQ section of</span> <a title="CNCMCodes.com website" href="http://www.cncmcodes.com/hp-7s-2">7 Easy Steps to CNC Programming: Book II, Beyond the Beginning</a>.</p>
<h4><span style="color:#000080;">CNC Tool Nose Radius </span></h4>
<p><span style="color:#000080;">Lathe tools rarely have a perfectly sharp corner at the tool nose.  As a result, when you program lathes, it is important to compensate for the tool nose radius.<br />
  </span><br />
<span style="color:#000080;">As you look at the tool nose radius example below, imagine these two situations.  Assume you are using a tool with a .031 nose radius.  As you cut down the face of the part, if you stop at X0, the tool, the actual cut will be .031 above the center of the part, leaving a .062 nub at the center of the part.  Then if you want to drill a hole in the center of the part, the drill walks off center because of the nub.</span></p>
<p><a href="http://cnctips.files.wordpress.com/2011/09/toolnoseradius.jpg"><img class="aligncenter size-full wp-image-496" title="Lathe Tool Nose Radius" src="http://cnctips.files.wordpress.com/2011/09/toolnoseradius.jpg?w=500" alt="Lathe Tool Nose Radius"   /></a></p>
<p>&nbsp;</p>
<p><span style="color:#000080;">In another situation, assume you are using the same tool to cut a profile.  If the program does not compensate for the tool nose radius the part will be cut under / over size.  <br />
</span> <br />
<span style="color:#000080;">The solution is to program the desired tool path relative to the center of the cutter.  This is true for lathes as well as mills. <br />
</span> <br />
<span style="color:#000080;">When programming a lathe, use the center of the tool nose radius.  This is particularly important when manually programming machines.  If you are generating G-code using a Computer Aided Manufacturing (CAM) system this is less critical.<br />
  </span><br />
<span style="color:#000080;">Programming to the center of the cutter is essential for correctly applying the math to generate accurate machine control data.<br />
 <br />
<a href="http://cnctips.files.wordpress.com/2011/09/milltooloffsets.jpg"><img class="aligncenter size-full wp-image-498" title="CNC Mill Tool Radius Offsets" src="http://cnctips.files.wordpress.com/2011/09/milltooloffsets.jpg?w=500" alt="CNC Mill Tool Radius Offsets"   /></a></span></p>
<p><span style="color:#000080;"> Fig. 13  (from</span> <a title="CNCMCodes.com website" href="http://www.cncmcodes.com/hp-7s-2">7 Easy Steps to CNC Programming: Book II, Beyond the Beginning</a><span style="color:#000080;">) above shows how a 1.00” cutter must be programmed so that there is 5” between parallel cuts if you need the part 4” wide.  </span><br />
<span style="color:#000080;">  </span><br />
<span style="color:#000080;">Examine the previous Tool Nose Radius example. Notice that if you program using the center of the tool nose radius, programming an X0 will move the tool so that its center stops at the center of the part.  That’s the good news.  The bad news is that the tool would then cut with the center of the tool on the profile, thus making the part too small.</span><br />
<span style="color:#000080;">  </span><br />
<span style="color:#000080;">You must compensate the tool path for the tool nose radius by adding the tool nose radius to the part diameter.  For example assume the following:  </span></p>
<ul>
<li><span style="color:#000080;">The the small diameter of the finished part is 1.000</span></li>
<li><span style="color:#000080;">The Tool Nose Radius is .031</span></li>
<li><span style="color:#000080;">The machine is programmed in the radius mode</span></li>
<li><span style="color:#000080;">The program is written for the center of the tool nose radius</span></li>
</ul>
<p><span style="color:#000080;">In this case, the center of part would be programmed as X.0 Z.031. The X dimension to turn the diameter would be X.531.  </span><br />
<span style="color:#000080;">  </span><br />
<span style="color:#000080;">Many lathes let you enter diameters instead of radii.  In this case, the center of part would be programmed as X.0 Z.031. The X dimension to turn the diameter would be X1.062, the diametrical result of changing the cutting radius by .031.</span><br />
<span style="color:#000080;">  </span><br />
<span style="color:#000080;">So, when facing to the center of a work piece with a .031” radius tool, you can actually program the cutter to go to X0</span></p>
<p><span style="color:#000080;">Note:  The above descriptions are &#8220;old school&#8221; in that most machines on the shop floor today have offsets for tool nose radius.  Using offsets allows you to program right to the dimensions of the part.  But goodCNC programmers know that, just because the machine can do something, does not excuse them for knowing how it works or how to do it manually.</span></p>
<p>&nbsp;</p>
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			<media:title type="html">Lathe Tool Nose Radius</media:title>
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		<title>Use Sub Programming to make your own canned cycles</title>
		<link>http://cnctips.wordpress.com/2011/08/20/sub-programming_to_make_canned_cycles/</link>
		<comments>http://cnctips.wordpress.com/2011/08/20/sub-programming_to_make_canned_cycles/#comments</comments>
		<pubDate>Sat, 20 Aug 2011 16:33:11 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Canned Cycles]]></category>
		<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[G Codes]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>
		<category><![CDATA[Manual Data Input]]></category>
		<category><![CDATA[MDI]]></category>
		<category><![CDATA[Sub Programming]]></category>

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		<description><![CDATA[Canned Cycles used in NC programming are great time savers, but often don&#8217;t do exactly what we want them to. Gopal posted a great question today about the limitations of the G83 canned cycle.  Here is what he had to say after reading Proven Tips and Tactics: Understanding Canned Cycles. [ I need to drill 200 [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=482&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><span style="color:#000080;">Canned Cycles used in NC programming are great time savers, but often don&#8217;t do exactly what we want them to.</span></p>
<p><span style="color:#000080;">Gopal posted a great question today about the limitations of the G83 canned cycle.  Here is what he had to say after reading</span> <a title="Proven Tips and Tactics: Understanding Canned Cycles" href="http://cnctips.wordpress.com/2010/06/13/cannedcycles/" target="_blank">Proven Tips and Tactics: Understanding Canned Cycles</a>.</p>
<p style="padding-left:30px;"><span style="color:#888888;">[<em> I need to drill 200 holes of Diameter 4.0mm to a depth of 50mm (Z-50.0) and then continue Diameter 3.0mm to a depth of 110.0mm (Z-110.0).</em></span></p>
<p style="padding-left:30px;"><span style="color:#888888;"><em>There is no problem for drilling Dia 4.0 upto Z-50.0 wirh a G83 code. But the Diameter 3.0mm hole, I want to go rapid upto Z-50.0 (because already drilled Dia 4.0 upto this depth) and then peck 2mm and clear the chip at Z3.0 and continue 2mm peck and clear chips at Z3.0 until Z-110. reaches. Is there any way I can do this in Fanuc or Sinumerik? If I give the R value 3.0, The drilling cycle starts from Z3 and lot of time wastage. If I give the R value -50.0, The chip is clearing at z-50 and not Z3. Any solution for this?</em> ] &#8211; Gopal</span></p>
<p><span style="color:#000080;"><span style="color:#888888;">    <span style="color:#000080;">That is an interesting situation and one that can be solved, not with canned cycles, but</span></span> with sub programming.</span></p>
<p><span style="color:#000080;">Sub programming techniques allow us to creat our own <a title="More on CNC Canned Cycles" href="http://cnctips.wordpress.com/category/cnc-programming/cnc-canned-cycles/">CNC canned cycles</a>.  While they may take a little effort to create in the beginning, once created they can be use over and over.  </span></p>
<h4><span style="color:#000080;">So what are CNC sub programs and how do you use them?</span></h4>
<p><span style="color:#000080;">Sub-program are similar to any other NC / CNC program except they are usually more simple.  Generally, sub-programs will only be a series of moves or positions.</span></p>
<p><span style="color:#000080;">The significant difference in a sub-program is that the end code will be an <strong>M99</strong>.  The M99 commands the control to return to program from which the sub-program was called.</span></p>
<p><span style="color:#000080;">When you want to call up a sub-program, use the command M98P(xxxx).  <strong>M98</strong> commands the control to leave the current program and complete the instructions in the sub program specified by the P-code.</span></p>
<p><span style="color:#000080;">THE FOLLOWING IS A DIAGRAM OF THE SUB-PROGRAM PROCESS</span></p>
<div id="attachment_484" class="wp-caption aligncenter" style="width: 510px"><a href="http://cnctips.files.wordpress.com/2011/08/subprogram.jpg"><img class="size-full wp-image-484 " title="SubProgram" src="http://cnctips.files.wordpress.com/2011/08/subprogram.jpg?w=500&#038;h=230" alt="CNC Sub Programming Example" width="500" height="230" /></a><p class="wp-caption-text">From 7 Easy Steps to CNC Programming P.48</p></div>
<p><span style="color:#000080;">To interpret this diagram start at the beginning.  As you read down you see at line n30 the program calls, with an M98, the sub program 80.  Moving through program 80 at line n15 the sub-program 85 is called.  Program 85 runs down to the M99 which returns control to program 80.  Program 80 continues processing until it reaches its M99 command.  This M99 returns control to the main program.  </span></p>
<p><span style="color:#000080;">From here the main program continues until it gets to line n70 where the control is once again passed to programs 80 and 85.  After programs 80 and 85 finish their processing the control is returned to the main program which continues until it reaches the end of the program at the M30.</span></p>
<p><span style="color:#000080;">You see from the example above, CNC controls allow sub programs to be nested.   This can be very useful too.</span></p>
<h4><span style="color:#000080;">So how could we use CNC sub programming to address Gopal&#8217;s Question?</span></h4>
<p><span style="color:#000080;">Starting the main program, it could be structured something like this?</span></p>
<h4>MAIN CNC PROGRAM   750</h4>
<p><span style="text-decoration:underline;"><span style="color:#ff0000;text-decoration:underline;">NOTE: THIS CODE IS FOR REFERENCE ONLY!  IT HAS NOT BEEN TESTED FOR ERRORS</span></span></p>
<p style="padding-left:30px;"><span style="color:#888888;">O750 <em>(main program)</em></span><br />
<span style="color:#888888;">N005 <em>(these are the ) </em></span><br />
<span style="color:#888888;">N010 <em>(typical start up)</em></span><br />
<span style="color:#888888;">N015 <em>(blocks you normally)</em></span><br />
<span style="color:#888888;">N020 <em>(to prepare the machine)</em></span><br />
<span style="color:#888888;">N025 G0 X  Y <em>(position to first hole)</em></span><br />
<span style="color:#888888;">N030 G43/G44 Z3.0 <em>(rapid to Z using your offset mode)</em></span><br />
<span style="color:#888888;">N035 M98 P751<em> (call sub program 751)</em></span><br />
<span style="color:#888888;">N040 G0 X Y <em>(move to new position)</em></span><br />
<span style="color:#888888;">N045 M98 P751 <em>(call sub program 751 again)</em></span><br />
<span style="color:#888888;">N050 G0 X Y <em>(repeat until all holes complete)</em></span><br />
<span style="color:#888888;">N055 &#8230;&#8230;..</span><br />
<span style="color:#888888;">N060 &#8230;&#8230;&#8230;</span><br />
<span style="color:#888888;">N065 G0 G28 G91 Z0 M9 <em>(safely return to Z home)</em></span><br />
<span style="color:#888888;">N070 G28 X0 Y0 M5 <em>(return to tool change position)</em></span><br />
<span style="color:#888888;">N075 M0 M1 / M30 / M2 &#8211; <em>(however you want to terminate the process)</em></span></p>
<p><span style="color:#000080;">Notice this Main CNC program only sets the machine in motion and moves to the location of the first hole.  The main program does not do any drilling in this example.  The actual drilling will be accomplished by the sub program shown below.   </span></p>
<p><span style="color:#000080;">It&#8217;s a little long, but in a few lines you will see the pattern of what the CNC sub program doing.   After the first few lines, you will see that the only change is in the drilling depth of each pass.</span></p>
<p><strong>CNC SUB PROGRAM 751  </strong></p>
<p style="padding-left:30px;"><span style="text-decoration:underline;"><span style="color:#ff0000;text-decoration:underline;">NOTE: THIS CODE IS FOR REFERENCE ONLY!  IT HAS NOT BEEN TESTED FOR ERRORS</span></span></p>
<p style="padding-left:30px;"><span style="color:#808080;">O751 <em>(sub program to do drilling)</em></span><br />
<span style="color:#808080;">Z-50. <em>(rapids to Z-50.0 to save time)</em></span><br />
<span style="color:#808080;">G1 Z-52.0 Fxxx  <em>(Drills to depth at desired feed rate)</em></span><br />
<span style="color:#808080;">G0 Z3.0  <em>(rapids to Z3.0 to clear chips)</em></span><br />
<span style="color:#808080;">Z-50.0  <em>(rapids to Z-50.0 to save time)</em></span><br />
<span style="color:#808080;">G1 Z-54.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-56.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-58.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-60.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-62.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-64.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-66.0</span><br />
<span style="color:#808080;">G0 Z3.0</span></p>
<p style="padding-left:30px;"><span style="text-decoration:underline;"><span style="color:#ff0000;text-decoration:underline;">NOTE: THIS CODE IS FOR REFERENCE ONLY!  IT HAS NOT BEEN TESTED FOR ERRORS</span></span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-68.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-70.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-72.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-74.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-76.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-78.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-78.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-80.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-82.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-84.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-86.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-88.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-90.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-92.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-94.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-96.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-98.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-100.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-102.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-104.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-106.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-108.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">Z-50.0</span><br />
<span style="color:#808080;">G1 Z-110.0</span><br />
<span style="color:#808080;">G0 Z3.0</span><br />
<span style="color:#808080;">M99 <em>(retuns control to the main program where it left off)</em></span></p>
<p> <span style="color:#000080;">The CNC sub program may look a little intimidating to write but it wasn&#8217;t.  Once I had the structure correct for the first few lines, I cut-n-paste the rest of the program.   All I had to do after that was to edit the lines for the drilling depth.  All other lines stayed the same.</span></p>
<h4><span style="color:#000080;">So How is the CNC sub program reusable like canned cycles?</span></h4>
<p><span style="color:#000080;">If your CNC control is capable of sub programming, and most controls are these days, any NC program can call any available sub program.  So, in this case, any program that has the line<br />
    M98 P751<br />
will call this exact sub program.</span></p>
<h4><span style="color:#000080;">But wait, isn&#8217;t this useful only if I want to drill these exact holes in some other part?</span></h4>
<p><span style="color:#000080;">Yes and no.  That is true if you don&#8217;t edit the code.   But once you have made a template for a sub program, you can reuse the structure but change the start, stop, clearance points and so on.  Once you have made the new sub program simply save it as a different number.</span></p>
<p><span style="color:#000080;">A good strategy is to reserve a set of numbers for your sub programs.   For example, you might store all your sub programs in the 5000 series of numbers.  Your first sub program would be 5000, the next 5001 and so on.</span></p>
<p><span style="color:#000080;">You can even get more creative with your numbering.   Sub programs 5000-5099 could be drilling sub programs.   Sub programs 5100-5199 could be sub programs to mill pockets.  Sub programs 5200-5299 could be sub programs for some other repetitive features, and so on.</span></p>
<h4><span style="color:#000080;">Sub programs are not just for drilling.</span></h4>
<p><span style="color:#000080;">You probably realized from the creative numbering examples above, that sub programs are not limited to drilling routines.   Sub programs can be used for any feature or shape, or for changing pallets, indexing table, or whatever.   Any repetitive CNC commands you do can be put in a sub program.</span></p>
<p><span style="color:#000080;">Great question Gopal, thanks for asking.</span></p>
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		<title>More on feedrates from SME</title>
		<link>http://cnctips.wordpress.com/2011/08/14/more-on-feedrate/</link>
		<comments>http://cnctips.wordpress.com/2011/08/14/more-on-feedrate/#comments</comments>
		<pubDate>Sun, 14 Aug 2011 06:25:41 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[Feeds and Speeds]]></category>
		<category><![CDATA[Production Management]]></category>
		<category><![CDATA[Cutting Speed]]></category>
		<category><![CDATA[cutting tools]]></category>
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		<description><![CDATA[After reading this article, DAVE DAVIDSON (SOCIETY OF MANUFACTURING ENGINEERS, Co-Chair:MMR Tech Comm &#124; Advisor: DESC Deburring/Surface Conditioning Tech Group)  provided a couple links to some very informative articles published by SME - Check them out.

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			<content:encoded><![CDATA[<p>After reading the previous article on the importance of feedrates,  DAVE DAVIDSON (SOCIETY OF MANUFACTURING ENGINEERS, Co-Chair:MMR Tech Comm | Advisor: DESC Deburring/Surface Conditioning Tech Group)  provided a  link to a very informative article published by SME &#8211; Check it out.</p>
<p><a href="http://dryfinish.wordpress.com/2011/07/14/microfinishing-and-surface-textures/">http://dryfinish.wordpress.com/2011/07/14/microfinishing-and-surface-textures/</a></p>
<p><a href="http://dryfinish.wordpress.com/2011/07/28/microfinishing-and-surface-textures-part-2/">http://dryfinish.wordpress.com/2011/07/28/microfinishing-and-surface-textures-part-2/</a></p>
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		<title>The Importance of Feedrate calculations and how to make them</title>
		<link>http://cnctips.wordpress.com/2011/08/13/feedrate-calculations/</link>
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		<pubDate>Sat, 13 Aug 2011 20:38:45 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[CNC Programming]]></category>
		<category><![CDATA[Feeds and Speeds]]></category>
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		<category><![CDATA[G94]]></category>
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		<description><![CDATA[Feedrate, the speed at which the cutting tool engages the part, is directly related to safety, productivity, tool life, surface finish, part quality and so on.  Let's look at these individually<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=462&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><span style="color:#003366;">One of the most important calculations you need to understand as a machinist or CNC programmer is the feedrate calculation.</span></p>
<h4><span style="color:#003366;">Why are feedrate calculations so important?</span></h4>
<p><span style="color:#003366;">Feedrate, the speed at which the cutting tool engages the part, is directly related to safety, productivity, tool life, surface finish, part quality and so on.  Let&#8217;s look at these individually.</span></p>
<ul>
<li><span style="color:#003366;"><strong>Safety</strong> - Feedrates determine cutting forces.  The faster you attempt to remove the material the greater the cutting forces.   So, the faster you cut the part, the more rigid you set up needs to be.  Anyone who has ever been around a machine when a cutting tool crashed into a part at rapid travel knows the damage that can be cause by excessive feedrates.<br />
 <br />
</span><span style="color:#003366;">Also, combined with tool geometry, the feedrate you use affects the chips that are made during the cutting process.   If the feedrate is too slow the cut material will not break into small chips and will create long stringers that whip around the spindle.   Stringers are very dangerous and can severely cut people, remove limbs, and so on.<br />
   </span></li>
<li><span style="color:#003366;"><strong>Productivity</strong>- obviously for production machining you want to cut the part as fast as possible without endangering people or machines or diminishing the quality of the part.  Some may disagree, but the fact is few things cost more spindle time.  <br />
   <br />
</span><span style="color:#003366;">For round numbers imagine you borrowed$100,000 for a machine at 10% interest. Just the interest on the machine is costing you $1.60 per hour.   If you only run the machine 1 shift per day, the cost is really $4.80 per hour. . . just to pay the interest.   Now if you want a 5 year pay back on the machine, that adds another $9.60 to the cost.<br />
  <br />
</span><span style="color:#003366;">To break even on the $100,000 machine loan at 10% interest, that machine needs to earn $14.42 per hour or about a quarter per minute.   And that does not even include wages, benefits, profit, G&amp;A, marketing etc.</span><span style="color:#003366;">Are you starting to get the picture.<br />
  </span></li>
<li><span style="color:#003366;"><strong>Tool Life</strong> - But what about tool life you ask?  Don&#8217;t aggressive feedrates reduce tool life? They can and the tooling cost is a consideration, but compared to inefficient spindle time, the cost is minor.<br />
  <br />
</span><span style="color:#003366;">The faster you cut the more pressure you put on the tool cutting edges and those forces tend to wear the tool more.   By the same token, cutting some materials too slow will work harden the material in front of the tool causing very rapid tool wear because of having to cut hard material.</span><br />
  </li>
<li><span style="color:#003366;"><strong>Surface Finish</strong> - Surface finish is directly related to feedrate and tool geometry.  Cut too fast with a tool nose radius that is too small and you will get a course finish.  A perfect example is threading on a lathe.   The tool is moving very fast in relationship to the spindle speed.   A face mill moving too fast in relation to spindle speed tends to leave a grooved pattern.<br />
    <br />
</span><span style="color:#003366;">Surface finish is also directly related to cost.   If the customer requirement allows for a 125 finish and your cutting process is giving them a 32 or 60 finish, you may be cutting too slow, wasting machine time, and increasing your cost of production.<br />
   </span></li>
<li><span style="color:#003366;"><strong>Part Quality</strong> - Customers don&#8217;t usually want low quality parts.  But what does that mean?  If a customer requirement is for a 125 surface finish, is a part with a 32 finish higher quality?  Print tolerances and surface finishes, when stated correctly, give the customer exactly what they need at the best possible price.   If the requirement is for a 125 finish, the customer is saying they don&#8217;t want to pay for the additional cost to achieve a 32 finish.  Now they may prefer a 32 finish, they just don&#8217;t really need it or want to pay extra to get it.<br />
  <br />
</span><span style="color:#003366;">So cut as aggressively as you can to meet the requirement and charge accordingly.   That means, if you are giving the customer a 125 finish, they should be paying less money they would to a vendor giving them a 32 finish.   If the 32 finish is that important to the customer, they need to update their requirements.<br />
  <br />
</span><span style="color:#003366;">The cutting forces associated with machining can also distort parts or introduce residual stresses.  So cutting too aggressively may distort the part in such a way that it diminishes overall quality.  It may take some trial and error finding the optimum feedrate.</span></li>
</ul>
<h4><span style="color:#003366;">Whoa you say, there is a lot more to it that feedrates!</span></h4>
<p><span style="color:#003366;">You are correct.  Feedrates are only one variable in a fairly complex process.  All of the following come into play when machining a part.</span></p>
<ul>
<li><span style="color:#003366;">Cutting speed </span></li>
<li><span style="color:#003366;">Feedrate</span></li>
<li><span style="color:#003366;">Depth of Cut</span></li>
<li><span style="color:#003366;">Machinability of the material (i.e. less machinable = more difficult to cut)</span></li>
<li><span style="color:#003366;">Rigidity of the set up</span></li>
<li><span style="color:#003366;">Rigidity of the machine</span></li>
<li><span style="color:#003366;">Horsepower of the spindle</span></li>
<li><span style="color:#003366;">Geometry of the cutting tool</span></li>
</ul>
<p><span style="color:#003366;">All of these variables affect the efficiency of the machining process and quality of the part.  But for this article the focus is limited to feedrates.  But there is a way to think about it to help keep it straight in your mind.  I promise after this section, I will show how to do the feedrate calculations but you need to have the right mindset so keep you safe and productive.</span></p>
<p><span style="color:#003366;">When you think of productivity, think of <em><span style="text-decoration:underline;">Cubic Inches of Material Removal Per Minute</span></em><span style="text-decoration:underline;"><strong>  </strong></span><strong></strong>Let&#8217;s call this the Material Removal Rate or <strong>MRR</strong>.  </span></p>
<ul>
<li><span style="color:#003366;">MRR is a function of Depth of Cut, Feedrate and Cutting (spindle) speed.</span></li>
<li><span style="color:#003366;">The greater the MRR, the greater the cutting forces.</span></li>
<li><span style="color:#003366;">The less machinable the material the greater the cutting forces</span></li>
<li><span style="color:#003366;">The greater the cutting forces, the greater the requirement for horsepower and rigidity. </span></li>
<li><span style="color:#003366;">Tool geometry affects cutting forces.  </span></li>
<ul>
<li><span style="color:#003366;">Positive cutting geometry tends to reduce cutting forces but the tool is weaker and often chip control is sacrificed.  </span></li>
<li><span style="color:#003366;">Negative cutting geometry typically increases cutting forces but has the benefit of stronger tools and better chip control.</span></li>
<li><span style="color:#003366;">Material properties and finish requirements often define the optimum tool geometry for the process.</span></li>
</ul>
</ul>
<h4><span style="color:#003366;">How feedrates are calculated.</span></h4>
<h4><span style="color:#003366;">G95 Cutting in units per revolution</span></h4>
<p><span style="color:#003366;">The simplest feedrate calculation is the G95 or feed per revolution (IPR) used mostly for lathe machining.  </span></p>
<p><span style="color:#003366;"><strong>FORMULA: </strong>Desired chip load * number of cutting edges</span></p>
<p><span style="color:#003366;">There really is not much calculation to do because you typically have one cutting tip cutting so if you want .030 chip load that equates to .030 feed per revolution of the spindle your program would include a G95 to set the cutting mode to IPR.  Then on the cutting line, you would have an F.03 </span></p>
<p><span style="color:#003366;"><strong>EXAMPLE:</strong>  G00 G80 G95       . . . start-up block to set modal conditions<br />
                         X### Z###              . . . positioning move to X, Z start of cut on a lathe<br />
                        G01 Z-1.250 F.03   . . . cut Z-1.25 inches at .03 inches per revolution</span></p>
<p><span style="color:#003366;">NOTE:  if you are programming in Metric Mode, you would use mm/minute.  For example, your feedrate would be F1.5 to feed 1.5 milimeters per minute.</span></p>
<p><span style="color:#003366;"><strong>EXAMPLE:</strong>  G00 G80 G95     . . . start-up block to set modal conditions</span><br />
<span style="color:#003366;">                         X### Z###            . . . positioning move to X, Z start of cut on a lathe</span><br />
<span style="color:#003366;">                        G01 Z-125.0 F1.5  . . . cut Z-125.0 mm at 1.5 mm per revolution</span></p>
<p><span style="color:#003366;">Suppose you are drilling though.  In this case you have 2 cutting tips so to maintain a .030 chip load, you would program G95 with a feedrate of F.060</span></p>
<p><span style="color:#003366;"><strong>EXAMPLE:</strong>  G00 G80 G95     . . . start-up block to set modal conditions</span><br />
<span style="color:#003366;">                         X### Z###            . . . positioning move to X, Z start of cut on a lathe</span><br />
<span style="color:#003366;">                        G01 Z-1.250 F.06 . . . drill Z-1.25 inches deep at .06 IPR  (.03 per cutting edge)</span></p>
<h4><span style="color:#003366;">G94 &#8211; Cutting using units per minute instead of units per revolution</span></h4>
<p><span style="color:#003366;">For mills, routers, drilling machines and some older machines, the typical feed rate is expressed in units per minute.  In other words, a feedrate might be 10 inches per minute or 250 mm per minute.  This can be a little confusing because, what we are interested in is our actual chip load.</span></p>
<p><span style="color:#003366;"><strong>FORMULA: </strong>Desired chip load * number of cutting edges * RPM<br />
</span></p>
<p><span style="color:#003366;"><strong>Lathe Example: </strong> .015 chip load * 500 RPM * 1 cutting edge = 7.5 IPM<br />
</span><span style="color:#003366;">                        G00 G80 G94         . . . start-up block to set modal conditions<br />
                         G97 S500               . . . set spindle in direct spindle speed mode and RPM at 500<br />
                         X### Z###            . . . positioning move to X, Z start of cut on a lathe<br />
                        G01 Z-1.250 F7.5 . . . cut Z-1.25 inches at 7.5 IPM to achieve .015 chip load</span></p>
<p><span style="color:#003366;"><strong>Lathe Drilling Example: </strong> .015 chip load * 500 RPM * 2 cutting edges = 15.0 IPM<br />
</span><span style="color:#003366;">                        G00 G80 G94            . . . start-up block to set modal conditions</span><br />
<span style="color:#003366;">                         G97 S500                  . . . Set Spindle in direct spindle speed mode and RPM at 500</span><br />
<span style="color:#003366;">                         X### Z###               . . . Positioning move to X, Z start of cut on a lathe</span><br />
<span style="color:#003366;">                        G01 Z-1.250 F15.0  . . . Cut Z-1.25 inches at 15.0 IPM to achieve .015 chip load/edge</span></p>
<p><span style="color:#003366;"><strong>Milling Example: </strong> .005 chip load * 2000 RPM * 4 cutting edges = 40.0 IPM<br />
</span><span style="color:#003366;">                         G00 G80 G94            . . . start-up block to set modal conditions</span><br />
<span style="color:#003366;">                         G97 S2000                . . . Set Spindle in direct spindle speed mode and RPM at 500</span><br />
<span style="color:#003366;">                         X### Y###               . . . Positioning move to X, Y start of cut on a lathe<br />
                         Z-###                          . . .  Positions end mill to proper depth to begin cut</span><br />
<span style="color:#003366;">                        G01 X2.5 F40.0        . . . Cut along X axis for 2.5 inches at 40 IPM to achieve .002 chip<br />
                                                                         load per edge</span></p>
<p><span style="color:#003366;">Again, if programming in metric mode, units would be changed to millimeters.</span></p>
<p><span style="color:#003366;">G93 is the code for Inverse Time feed rates and is beyond the scope of this article but for a good discussion on the subject check out this article on Eng-Tips forum  <a href="http://www.eng-tips.com/viewthread.cfm?qid=200454&amp;page=7">http://www.eng-tips.com/viewthread.cfm?qid=200454&amp;page=7</a></span></p>
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		<title>How to make cutting speed calculations</title>
		<link>http://cnctips.wordpress.com/2011/04/25/cutting-speed-calculations/</link>
		<comments>http://cnctips.wordpress.com/2011/04/25/cutting-speed-calculations/#comments</comments>
		<pubDate>Mon, 25 Apr 2011 06:15:11 +0000</pubDate>
		<dc:creator>davidhayden</dc:creator>
				<category><![CDATA[Feeds and Speeds]]></category>
		<category><![CDATA[Learning CNC Programming]]></category>
		<category><![CDATA[Uncategorized]]></category>
		<category><![CDATA[Cutting Speed]]></category>
		<category><![CDATA[Manual Data Input]]></category>
		<category><![CDATA[MDI]]></category>
		<category><![CDATA[Speeds and Feeds]]></category>

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		<description><![CDATA[Recently a reader asked a great question about how to calculate speeds and feeds. 
Speeds and feeds are at the heart of all machining and there is much to consider. 
<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=cnctips.wordpress.com&amp;blog=12213643&amp;post=453&amp;subd=cnctips&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><span style="color:#000080;">Recently a reader asked a great question about how to calculate speeds and feeds. </span></p>
<p><span style="color:#000080;">Speeds and feeds are at the heart of all machining. Learning the CNC codes or using a conversational control can be achieved in a relatively short period of time. Selecting the right speeds and feeds is almost as much art as it is science.</span></p>
<p><span style="color:#000080;"> In this article, I will be discussing how to calculate cutting speeds, but before we get into details, here are a few things to keep in mind. (at the bottom are calculations for speeds and feeds)</span></p>
<ol>
<li><span style="color:#000080;"><strong>Safety</strong> &#8211; always an important consideration &#8211; don&#8217;t jeopardize your or another operators safety for the sake of speed.</span><br />
<span style="color:#000080;"> </span></li>
<li><span style="color:#000080;"><strong>Rigidity</strong> &#8211; if your setup is not rigid, you can toss a part or tool out of the machine, experience excessive chatter, fail to achieve acceptable surface finish, fail to maintain dimensions and so on.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Machinability</strong> – all materials have unique machinability characteristics. You&#8217;ve no doubt observed aluminum machines easier than steel.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Cutting Toom Material -</strong> high speed steel, carbide, ceramic, etc.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Available Horsepower</strong> – Machinability determines the horsepower requirements to cut the material. If you don&#8217;t have the horsepower, you will have to lighten your cuts to avoid stalling the spindle.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Tool geometry</strong>- Tools that have positive cutting geometry cut more freely than do tools with negative geometry, but are limited in the amount of shock and interrupted cuts they can take. Some materials cut much better with negative geometry, others with neutral or positive geometry.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Heat</strong> – machining creates a lot of heat and it is going to go into the tool, the material, the chips that are removed and so on.  Too much heat will quickly break down your tool. Too much heat can cause the material to expand and make it difficult to control part size.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Chip control</strong> – your ability to control the chips made during the machining process is an indication of having chosen the correct speeds, feeds and tool geometry.</span><br />
<span style="color:#000080;">  </span></li>
<li><span style="color:#000080;"><strong>Surface Finish</strong> – there is a direct relationship between cutting feeds and tool radius to surface finish.</span></li>
</ol>
<p><span style="color:#000080;">All of the above factors (and many more) affect or are directly affected by speeds and feeds.</span></p>
<p><span style="color:#000080;">With respect to machinability, there are numerous websites that outline the machinability of various materials. Many tool manufacturing websites like Kennametal.com have great resources for determining the optimum cutting speeds and feeds for their tools and a wide variety of materials.</span></p>
<p><span style="color:#000080;">Cutting speed, in the US, is generally expressed in terms of Surface Feet Per Minute often expressed as (SFM) or (SFPM). SFM is the speed at which tool tip is cutting through the material. Imagine you are dragging a stick behind a car that is traveling at 60 miles per hour. In one minute your stick has traveled 5,280 feet across the ground. That would be expressed as 5,280 SFM.</span></p>
<p><span style="color:#000080;">Unless you are running a shaper or other linear cutting machine, your surface feet per minute is based upon the rotational speed of either the part or the cutting tool. Obviously, on a lathe it is the chuck speed that matters. On a milling machine it is the spindle speed that matters.</span></p>
<p><span style="color:#000080;">The other major factor in calculating SFM is the diameter of the diameter you are cutting on a lathe or the diameter of the tool you are using on the milling machine. So here are the steps to calculating SFM.</span></p>
<h4><span style="color:#000080;">For SFM / RPM calculations you need to know the following:</span></h4>
<p><span style="color:#000080;">D = the diameter of the milling tool or the diameter you are cutting on a lathe</span><br />
<span style="color:#000080;">Pi / π = 3.1416 (approximately but close enough)</span><br />
<span style="color:#000080;">SFM = The surface feet per minute you want to use for a cutting speed</span><br />
<span style="color:#000080;">RPM = The RPM required to achieve the desired SFM based on the diameter of the tool/part</span><br />
<span style="color:#000080;">K = Constant use for SFM calculations (3.8197)</span><br />
<span style="color:#000080;">    = 1 / [(D*π) /12]</span><br />
<span style="color:#000080;">    = 1/( 3.1416 /12)</span><br />
<span style="color:#000080;">     = 3.8197</span></p>
<h4><span style="color:#000080;"><strong>RPM Calculations when you know the SFM you want to achieve.</strong></span></h4>
<p><span style="color:#000080;">RPM = <span style="text-decoration:underline;">SFM * 3.8197<br />
</span>                            D</span><br />
<span style="color:#000080;">Example: You are cutting a 2.5 diameter on a part (or using a 2.5 dia milling cutter)</span></p>
<ul>
<li><span style="color:#000080;">Material is free machining steel</span></li>
<li><span style="color:#000080;">Cutting tool is coated carbide</span></li>
<li><span style="color:#000080;">Carbide manufacturer recommends 500 SFM</span></li>
</ul>
<p><span style="color:#000080;">Your cutting RPM would be:</span><br />
<span style="color:#000080;">             = (500 * 3.8197) / 2.5= 1909.85 / 2.5</span><br />
<span style="color:#000080;">             = 763.94</span><br />
<span style="color:#000080;">             = 764 RPM (rounded to the nearest RPM</span></p>
<h4><span style="color:#000080;"><strong>SFM calculations when you know the tool diameter and RPM</strong></span></h4>
<p><span style="color:#000080;">But what do you do if you know the diameter of the part or cutter diameter and the RPM but you need to know the SFM so you can verify if it is appropriate.</span></p>
<p><span style="color:#000080;">              SFM = <span style="text-decoration:underline;">RPM * Diameter<br />
</span>                                    3.8197</span></p>
<p><span style="color:#000080;">Example:</span></p>
<ul>
<li><span style="color:#000080;">You know the milling cutter is 6” in diameter</span></li>
<li><span style="color:#000080;">You know the RPM is 1000</span></li>
<li><span style="color:#000080;">You need to know is the SFM appropriate for cutting aluminum</span></li>
</ul>
<p><span style="color:#000080;">          SFM= (1000 * 6) / 3.8197</span><br />
<span style="color:#000080;">                   = 6000 / 3.8197</span><br />
<span style="color:#000080;">                   = 1570.80</span></p>
<p><span style="color:#000080;">Since cutting speeds for aluminum using carbide can range from 800-2000 SFM  1570.8 SFM  may or may not be a good speed. It will depend on all the factors listed at the beginning.</span></p>
<h4><span style="color:#000080;">Watch my next article that will discuss how to calculate feed rates for mills, drills and lathes.</span></h4>
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