Metal Removal Rate and Spindle Load

[wholaday3]

I wanted to get some feed back on the relationship between metal removal rate and spindle load.  With the three variables in MRR being feedrate, depth of cut, and stepover can you say that the spindle load will be the same no matter how you change the variables to keep the same MRR. I was wondering if you could put a value on the variable would feedrate consume the least amount of load, then depth of cut, then stepover.  If so then feedrate would be the most efficient way to remove stock material.  Any comments would be greatly appreciated.  Thanks.

[rrichard]

Check out G-Wizard

[crazy^millman]

I wanted to get some feed back on the relationship between metal removal rate and spindle load.  With the three variables in MRR being feedrate, depth of cut, and stepover can you say that the spindle load will be the same no matter how you change the variables to keep the same MRR. I was wondering if you could put a value on the variable would feedrate consume the least amount of load, then depth of cut, then stepover.  If so then feedrate would be the most efficient way to remove stock material.  Any comments would be greatly appreciated.  Thanks.

 

All things equal these 3 are not equal. In a Vacuum or perfect world where all things are constant and nothing ever changes. Where the tools always stay sharp and the material is always the same. Where the machine always feeds and same and the volume metric removal of the material will always stay the same you might could create a variable process that can take it into account, but there is the problem. We live in the real world where all machines are different, all materials cut differently and everything else has to be considered as part of the equation. The best teacher or answer is experience. There are many different factors to consider and the different tools out there to help you along are great, but getting in front of the machine. Hearing and experiencing what is going on is the best answer IMHO. Read all you want and see all the different videos, but until you are in the shop and cutting the part and see everything can you make best call on what is the variables needed to be effective. I like formulas they make up most of what we do day to day, but having made a bunch of dumb mistakes you figure out what works and what doesn't. Let us know what you work out be interesting to see what your research yields for results.

[Matthew Hajicek - Singularity]

HSMAdvisor will give spindle load and cutter deflection estimates, and limit speed and feed recommendations based on your machines capabilities.

[Machineguy]

Spindle load will vary by machine. Just keep a eye on it when running. Its also a good indicator when conditions change in a run like the tools are getting dull, material has work hardened, ect.

I listen for a sound change also.