Calculator Inputs
Example Data Table
| Material | Feed (mm) | Depth (mm) | Base Kc (N/mm²) | Chip Area (mm²) | Main Force (N) | Speed (m/min) | Power (kW) |
|---|---|---|---|---|---|---|---|
| Mild Steel | 0.20 | 2.00 | 1800 | 0.40 | 720.00 | 120 | 1.44 |
| Aluminum Alloy | 0.25 | 2.50 | 900 | 0.625 | 562.50 | 180 | 1.69 |
| Stainless Steel | 0.18 | 2.20 | 2400 | 0.396 | 950.40 | 95 | 1.50 |
These rows are illustrative examples for comparison and layout demonstration.
Formula Used
1) Uncut Chip Area
A = f × ap for feed and depth mode, or direct user input in chip area mode.
2) Effective Specific Cutting Force
kc,eff = kc × material factor × wear factor
3) Main Cutting Force
Fc = kc,eff × A
4) Feed and Radial Force
Ff = Fc × feed ratio and Fr = Fc × radial ratio
5) Resultant Force
R = √(Fc² + Ff² + Fr²)
6) Cutting Power
P(kW) = Fc × V / 60000
7) Required Machine Power
Preq = P / efficiency
8) Torque
T(N·m) = 9550 × Preq(kW) / rpm
How to Use This Calculator
- Select either Feed × Depth mode or Direct Chip Area mode.
- Choose a material preset, or enter a custom specific cutting force value.
- Enter feed, depth, or direct chip area based on your selected mode.
- Add cutting speed to estimate power and material removal rate.
- Enter spindle speed if you also want torque output.
- Adjust material and wear factors to reflect actual shop conditions.
- Use feed and radial force ratios to estimate additional cutting force components.
- Press Calculate Cutting Force to show the result above the form.
- Review the charts, then export the results as CSV or PDF.
FAQs
1. What is cutting force?
Cutting force is the resistance acting on a tool while it removes material. It directly affects tool life, machine loading, vibration risk, power demand, and part quality.
2. How is chip area estimated here?
In feed and depth mode, uncut chip area equals feed multiplied by depth of cut. In direct mode, you can enter the chip area directly from another method.
3. Why does material selection matter?
Different materials resist shearing differently. Harder or tougher materials usually need higher specific cutting force, which raises main force, power demand, and torque requirements.
4. What does the wear factor do?
A worn tool often cuts less efficiently and needs more force. The wear factor lets you increase the effective cutting force to reflect that real-world condition.
5. Why include feed and radial force ratios?
The main cutting force alone does not show the full load path. Feed and radial estimates help evaluate bearings, deflection, chatter risk, and workholding demands.
6. Why is torque unavailable without rpm?
Torque depends on both power and rotational speed. Without rpm, the calculator can still estimate force and power, but it cannot convert them into torque.
7. Can this calculator be used for milling and turning?
Yes, when you provide a suitable uncut chip area and reasonable specific cutting force. It is a practical engineering estimator, not a full process simulation model.
8. Are these results exact machine values?
No. Actual shop results also depend on tool geometry, coatings, runout, rigidity, coolant, engagement conditions, and material variability. Use this tool for strong first-pass estimates.