Method of determining feed rate and cutting speed for cutting metal and of predicting cutting effects
First Claim
1. In a system having a machine with a cutter for cutting a metal workpiece and a fixture for mounting the workpiece, a method of adjusting the feed rate and cutting speed for a machining operation to the characteristics of the material to be cut, the cut to be made, the fixture, the cutter, and the machine, said method comprising:
- determining a first set of parameters, including a preliminary cutting speed and a preliminary feed rate, from the characteristics of the material to be cut, the cut to be made, the fixture, the cutter, and the machine;
calculating the maximum allowable cutter force from the first set of parameters;
calculating a base cutting speed from the first set of parameters;
calculating the maximum feed rate from the first set of parameters, the maximum allowable cutter force, and the base cutting speed; and
designating the calculated base cutting speed as the initial cutting speed, and the calculated maximum feed rate as the initial feed rate, for the machining operation.
1 Assignment
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Accused Products
Abstract
A first set of parameters, including a preliminary cutting speed and a preliminary feed rate, is determined from the characteristics of the material to be cut, the cut to be made, the cutter, and the cutting machine. The hardness of the metal to be cut is coverted into Brinell hardness. The maximum allowable cutter force and a base cutting speed are calculated. The cutter force is the minimum of the maximum machine spindle side load and the forces required to: break the cutter at its shank, break the cutter at its flutes, and fracture the teeth. The maximum feed rate is calculated as the minimum of the maximum rates for: the desired surface finish, the maximum available horsepower, and the maximum force available. These calculation include correcting the maximum allowable cutter force and the maximum feed rate for fixture condition and machine condition and converting machine rate horsepower into spindle horsepower. Preferably, further calculations of cutting effects are made, including cutter deflection, actual cutting force, estimated tool life, and estimated surface finish. These effects may also be calculated separately using preset cutting speeds and feed rates.
33 Citations
32 Claims
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1. In a system having a machine with a cutter for cutting a metal workpiece and a fixture for mounting the workpiece, a method of adjusting the feed rate and cutting speed for a machining operation to the characteristics of the material to be cut, the cut to be made, the fixture, the cutter, and the machine, said method comprising:
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determining a first set of parameters, including a preliminary cutting speed and a preliminary feed rate, from the characteristics of the material to be cut, the cut to be made, the fixture, the cutter, and the machine; calculating the maximum allowable cutter force from the first set of parameters; calculating a base cutting speed from the first set of parameters; calculating the maximum feed rate from the first set of parameters, the maximum allowable cutter force, and the base cutting speed; and designating the calculated base cutting speed as the initial cutting speed, and the calculated maximum feed rate as the initial feed rate, for the machining operation. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. In a system having a machine with a cutter for cutting a metal workpiece and a fixture for mounting the workpiece, a method of adjusting maximum limits on horsepower, torque, and cutting force for a machining operation to the characteristics of the metal to be cut, the cut to be made, the cutter, the fixture, and the machine, said method comprising:
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selecting a fixed cutting speed and a fixed feed rate; determining a set of parameters from the characteristics of the metal to be cut, the cut to be made, the cutter, the fixture, and the machine; calculating cutting effects, including forces required to break the cutter, cutter deflection, actual cutting force, estimated cutter life, and estimated surface finish from the fixed cutting speed and feed rate and the set of parameters; and determining said maximum limits for the machining operation from the calculated cutting effects. - View Dependent Claims (32)
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Specification