Last update：18, July, 2021
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Milling Maniac :
Calculator Application
on Milling (Fraise) machining: How to use
How to use each calculation function are explained.
How to use：
- Machining Analysis
- Cutting condition
When cutting conditions are selected, material removal rate is important for productivity.
However, other factors are also important.
For example, tooth passing frequency is important on the vibration problem.
When the sampling is conducted with some measuring instruments, the number of sampling point per one revolution is important.
On this calculation function, these values are calculated.
- Undeformed chip thickness and Number of engaged cutting teeth on polygonal and round inserts
The torque is lower than the limitation of the main spindle.
The cutting force per one tool revolution affects the machining accuracy, the tool life and so on.
On this calculation function, these values are calculated.
- Chip flow direction based on Colwell Law
This function is used to check the scratch markes on the rake face.
However, you can check the chip flow direction by using the axial depth of cut and the nose radius.
- True Rake and Inclination Angle without insert R.R.
When the approach angle is larger than zero, the inclination angle is changed by the radial rake angle.
The inclination angle affect the chip evacuation.
The effect for inclination angle is calculated by this function.
- Ramping angle and Helical milling
The range of application of the ramping machining and the herical machining is affected with the insert shape.
This function is used to check the range.
- Distance at Ramping milling
The trigonometric function is only used.
- Heeling
In the past, heeling is conducted with inclining the main spindle directly.
At the present time, the main spindle is easily inclined with the five-axis machine tool.
Curved surface is able to be machined with the heeling.
- DTCR(Difficult-to-Cut Rating)
DTCR is able to be calculated by searching the material property on the internet.
DTCR is effective to understand the reason why it is difficult to machine the workpiece material.
- Run-out analysis
The run^out is evaluated with the maximum and the minimum values of relative tooth positions.
My guess is that the evaluation method is not good.
Relative tooth positions between neiboring teeth is important for the cutting force and the tool life.
The length of the minor cutting edge is important for the surface roughness.
These effects are evaluated.
- Temper color of steel
Relationships between the temper color and the oxide film thickness are shown here.
You can estimate the cutting temperature and modify the cutting speed and so on.
- Estimation of recommended cutting conditions on catalogue (Trial version)
It takes a time to open the catalogue to check the recommended cutting condition.
The recommended cutting condition is not often suitable for my cutting process.
The catalogue is not enough to check the specification of the cutting tool.
Thus, I try to find the effective method to use the catalogue data.
- Vibration Analysis
- Natural frequency and stiffness of a cantilevered round bar
The sfiffness and the vibration property of the cutting tool with the main spindle or the tool holder are calculated.
Especially, it is unique to calculate these values on the stepped cantilevered round bar.
It is interesting to compare these calculation results and the spectrum of the vibrations.
There are many application software for the spectrum analyser for sound.
- Frequency response on a vibrating system with one degree of freedom
The frequency response is calculated with the modal mass, the modal stiffness and the modal damping.
The frequency response is also calculated with the natural frequency and the damping ratio.
It is difficult to measure the damping.
- Dynamic balance
The centrifugal force by the dynamic balance and the required additional mass to refine the dynamic balance are calculated.
- Evaluation of balancing for variable weights
When you refine the dynamic balance, this fuction is usable.
- Unit Conversion
- Conversion between US customary units and International system of units
This function converts units for distances.
- Conversion Table of INCH and MM
It is easy to check the conversion by checking the table.
- Conversion between angles
This function converts units for angles.
- Theoretical conversion of Hardness for steel
This function conducts the theoretical conversion between hardness.
There are some conversion errors.
- Others
- List of trouble shootings
There are problems, trouble shooting lists and the reason.
- Recommended range of tightening torques on screw clamping
The research result of the recommended range of tightening torques on screw clamping is shown here.
You can calculate the relationship between the tighting torque and the axial force.
- Notification
There are notifications and web site links.