Radial chip thinning calculator
At less than half diameter engagement the chip is thinner than the feed per tooth. Failing to compensate is why light cuts burn tools.
rpm
Programmed feed per tooth
0.0833mm
- Feed rate
- 1500 mm/min
- Chip thinning factor
- 1.6667
- Radial engagement angle
- 36.87 degrees
- Feed rate without compensation
- 900 mm/min
- Speed-up from compensating
- 1.667
Show the working
- Cutter diameter = 10
- Radial depth of cut = 1
- Target chip thickness = 0.05
- Spindle speed = 6000
- Flutes = 3
- ratio = clamp(1 / 10, 0, 1) = 0.1
- Chip thinning factor = 0.1 >= 0.5 ? 1 : 1 / (2 * sqrt(0.1 * (1 - 0.1))) = 1.666 67
- Programmed feed per tooth = 0.05 * 1.666 67 = 0.083 333 3
- Feed rate = 0.083 333 3 * 3 * 6000 = 1500
- Radial engagement angle = deg(acos(clamp(1 - 2*0.1, -1, 1))) = 36.8699
- Feed rate without compensation = 0.05 * 3 * 6000 = 900
- Speed-up from compensating = 900 > 0 ? 1500 / 900 : 0 = 1.666 67
Values are shown to six significant figures here; the arithmetic itself runs on exact fractions and is only rounded where a number is printed.
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The formula
- chip thinning factor = 1 / (2 sqrt(ae/D x (1 - ae/D))) for ae/D below 0.5
- programmed feed per tooth = target chip thickness x factor
At 10% radial engagement the factor is 1.67, so the programmed feed should be two thirds higher than the target chip.
This is radial thinning only. Axial thinning applies as well with ball and toroidal cutters.