Engineering Calculator

INDEX

Page 1

INDEXSURFACE FINISH

TOLERANCE FINDER

QTY CHECK

CYCLE TIME CHECK

CUTTING SPEED

POWER CALCULATION

FORMING PRESURE

Note: This all calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for

tool design.

INDEX

Page 2

INDEXSPRING PRESURE

CUTTING FORCE

TOLERANCE

THREADING

AIR CYLINDER FORTCE

BEND VARIABLE

#POWER & TORQUE

Note: This all calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for

tool design.

INDEX

Page 3

SCREW STRENTH

WEIGHT CALCULATION

SPOT DRILL DEPTH

DEPTH OF CUT

MACHINE POWER(kw)

THREAD DEPTH CALCULATION

Powered by

SENKAMS SOLUTIONS LTD.,


Page 4

THREAD DEPTH CALCULATIONINPUT DETAILS

Thread pitch (mm) 1.25Thread depth (ap) 0.783No. of passes (nap) 15 Note:

1) Minimum entered 2 passes.RESULTS 2) Maximum entered 50 passes.

1st pass, radial infeed 0.115 0.1152nd pass, radial infeed 0.209 0.0953rd pass, radial infeed 0.296 0.0874th pass, radial infeed 0.363 0.0675th pass, radial infeed 0.419 0.0566th pass, radial infeed 0.468 0.0497th pass, radial infeed 0.513 0.0458th pass, radial infeed 0.554 0.0419th pass, radial infeed 0.592 0.03810th pass, radial infeed 0.628 0.03611th pass, radial infeed 0.662 0.03412th pass, radial infeed 0.694 0.03213th pass, radial infeed 0.725 0.03114th pass, radial infeed 0.755 0.03015th pass, radial infeed 0.783 0.02816th pass, radial infeed 0.81117th pass, radial infeed 0.83718th pass, radial infeed 0.86319th pass, radial infeed 0.88820th pass, radial infeed 0.91321st pass, radial infeed 0.93622nd pass, radial infeed 0.95923rd pass, radial infeed 0.98224th pass, radial infeed 1.00425th pass, radial infeed 1.02626th pass, radial infeed 1.04727th pass, radial infeed 1.06828th pass, radial infeed 1.088

GOTO INDEX

C5

Min-2 passes, Max-50 passes


Page 5

29th pass, radial infeed 1.10830th pass, radial infeed 1.12731st pass, radial infeed 1.14732nd pass, radial infeed 1.16633rd pass, radial infeed 1.18434th pass, radial infeed 1.20335th pass, radial infeed 1.22136th pass, radial infeed 1.23937th pass, radial infeed 1.25638th pass, radial infeed 1.27339th pass, radial infeed 1.29140th pass, radial infeed 1.30741st pass, radial infeed 1.32442nd pass, radial infeed 1.34143rd pass, radial infeed 1.35744th pass, radial infeed 1.37345th pass, radial infeed 1.38946th pass, radial infeed 1.40447th pass, radial infeed 1.42048th pass, radial infeed 1.43549th pass, radial infeed 1.45050th pass, radial infeed 1.465


Page 6

1) Minimum entered 2 passes.2) Maximum entered 50 passes.

SURFACE FINISH

Page 7

Surface Finish Rmax=(fn²/8*r£)*1000

Feed (fn)

Ra (normal insert)

Ra (wiper insert)

Surface Finish (feed calculation)

Ra

Feed (fn)

Tool nose radius-r£

Tool nose radius-r£

GOTO INDEX

SURFACE FINISH

Page 8

Surface Finish Rmax=(fn²/8*r£)*1000

0.2

0.4

12.500

6.250

Surface Finish (feed calculation)

0.8

0.40.051

SURFACE FINISH

Page 9

N12 50

N11 25

N10 12.5

N9 6.3

N8 3.2

N7 1.6

N6 0.8

N5 0.4

N4 0.2

N3 0.1

N2 0.05

N1 0.025

QTY CHECK

Page 10

QUANTITY CHECK

Working days/Month 30 daysworking hors/shift 5.0 hrsNumber of shift 1Cycle time / comp. 5 minutesTotal hrs/ day 5Total hrs/ Month 150Minutes/Month 9000Qty / Month 1800 nos

GOTO INDEX

CYCLE TIME CHECK

Page 11

CYCLE TIME CHECK

Working days/Monthworking hors/shiftNumber of shiftQty / MonthTotal hrs/ dayTotal hrs/ Monthminutes/Month

Cycle time / comp.

GOTO INDEX

CYCLE TIME CHECK

Page 12

CYCLE TIME CHECK

30 days7 hrs

210 nos

13390

234002340 min

140400 seconds

CUTTING SPEED

Page 13

CUTTING SPEED

Dia. of component

Spindle RPM

Feed (Fn)-mm/rev

Cutting speed (Vc)

Feed (Fn)-mm/min

Spindle RPMDia. of componentCutting speed (Vc)Spindle RPM

GOTO INDEX

CUTTING SPEED

Page 14

CUTTING SPEED

Ø 50.0

1000

0.2 mm/rev

Vc=157.08

mm/min=200.00

Spindle RPMØ 20.0

Vc=120.001909.859

POWER CALCULATION

Page 15

POWER CALCULATIONCUTTING SPEED, V m/minFEED RATE, f mm/revDEPTH OF CUT, d mmPOWER CONSTANT, KpFEED FACTOR FOR POWER CONSTANTS, CTOOL WEAR FACTOR, WMACHINE TOOL EFFICIENCY FACTOR, EMETAL REMOVAL RATE , Q cm³/sPOWER AT THE CUTTING TOOL, Pc kWPOWER AT THE MOTOR, Pm kW

GOTO INDEX

POWER CALCULATION

Page 16

POWER CALCULATION1800.5

51.69

1.30.94

0.87.50

15.4919.36

POWER & TORQUE

Page 17

Power Required W = Vc x f x Dp x Ps /( 6000 * E)

Cutting force - Fc= f x Dp x Ps / E

Cutting Torque - Tc = Fc x Dc/200

W- Power in KW Fc - Cutting Force Kg Tc - Cutting torque ( Nm ) V c - Cutting Speed in ( m/ min ) f - Feed in ( mm/rev )Dp - Depth of Cut in (mm) Ps - Specifica cutting energy ( kg/mm2 )E - Efficiency (0.8)Dc- Diameter of cutting ( mm )

Cutting force - Fc= f x Dp x Ps / E

Cutting Dia mm DP-mm 440 200 0.4 3 250 0.8 12.5

80 160 0.3 5 250 0.8 12.580 160 0.3 5 250 0.8 12.580 160 0.3 5 250 0.8 12.5

Torque Available Power ( Cont Power ( 30 min) Rpm Torque (100%) Torque (60 %)

18.5 22 200 883.375 1050.5

Ps for Steel 250 kg /mm2 Ps for Cat iron 210 Kg/mm2

Cutting Speed Vc ( m/min )

Feed ( mm/ rev )

Specific Cutting Energy KG /mm2 Efficiency

Power Req KW

POWER & TORQUE

Page 18

#INDEX

POWER & TORQUE

Page 19

Rpm144.7596989 300 825 573 1055.542

636.942675159 375 187.5 179.922 239.896636.942675159 375 187.5 179.922 239.896636.942675159 375 187.5 179.922 239.896

``

Cutting Force kg

Req Torque NM

Available Torque 100%

Available Torque 30 min

SPRING PRESURE

Page 20

Spring Pressure CalculatorLIGHT DUTY MEDIUM DUTY HEAVY DUTY EXTRA HEAVY DUTY

Free Length of Spring= 2.000 2.000 2.000 2.000Spring Force / .100"= 20 66 154 197

Preload= 0.125 0.125 0.125 0.125Travel= 0.125 0.125 0.125 0.125

Total Travel: 0.250 0.250 0.250 0.250% Compression: 13% 13% 13% 13%

Force / spring: 50 165 385 493

# of Springs= 10 10 10 10

Total Force: 500 1650 3850 4925

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

GOTO INDEX

SPRING PRESURE

Page 21

TONS LBS245 490000

19600


CUTTING FORCE

Page 22

Cutting Parameters

INPUT DATATOOL NUMBER 1PART NUMBER 2

Mild Steel Semi-hard MildCut Length= 25.000 25.000 25.000

Stock Thickness= 0.079 0.079 0.079Ultimate Shear Strength= 40,000 35,000 55,000

Cutting Force Required RESULTLBS: 79,000 69,125 108,625

TONS: 40 35 54

Stripping Force Required8% 6,3205% 3,9503% 2,370

Use The "Spring Pressure" Calculator To Determine The Required Number of Springs


GOTO INDEX

CUTTING FORCE

Page 23

Mild Stainless Tough Stainless25.000 25.0000.079 0.079

80,000 120,000

158,000 237,000 79 119


TOLERANCE

Page 24

Tolerance Transformation

DEVIATION TOLERANCE SYMETRIC TOLERANCEPlus= 2.00

Nominal= 100.00 Nominal 101.50 ± 1.50Minus= 1.00

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using

this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

GOTO INDEX

THREADING

Page 25

Thread CalculatorsFinds useful thread data.

ENGLISH TAP DRILLOUTSIDE DIA : Ø 0.500

%THREAD : 0.75PITCH (THD / INCH) : 13.00

TAP DRILL =

METRIC TAP DRILLOUTSIDE DIA : Ø 16.00 MM

%THREAD : 75.00METRIC PITCH : 1.00 MM

TAP DRILL : Ø 15.03 MM Ø 0.592

NUMBER THREADSTHREAD # : 7

MAJOR DIAMETER : Ø 0.151

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown

here should be verified by qualified personnel before use for tool design.

GOTO INDEX

AIR CYLINDER FORCE

Page 26

Air Cylinder Forces & Inputs

INPUT BORE DIA 2.000 INCHESRESULTING AREA= 3.142 SQUARE INCHESFORCE PER 10 PSI= 31.42 POUNDS OF FORCE

INPUT LINE PRESSURE 50 PSIFORCE= 157.08 POUNDS



Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be

verified by qualified personnel before use for tool design.

GOTO INDEX

AIR CYLINDER FORCE

Page 27



BEND VARIABLE

Page 28

Bend Variables

Set Radius Given Form RadiusForm Radius= R .032”

Stock Thickness= .0470”Degrees of Arc= 90.00ºNeural Axis (%)= 5%

RADIUS OF NEUTRAL AXIS: R .034”BEND DEDUCTION: .0532” 1.3505968

SET RADIUS (1.35 X STOCK): R .097”

Form Radius Given Set Radius(REFERENCE - BASED ON 8% THINNING)Set (Outside) Radius= R .060”

Stock Thickness= .0375”Degrees of Arc= 90.00ºNeural Axis (%)= 42%

RADIUS OF NEUTRAL AXIS: R .420”BEND DEDUCTION: .6598”

Form (inside) RADIUS: R .019”


GOTO INDEX

BEND VARIABLE

Page 29


CLEARENCE

Page 30

Clearance

5.0% 8.0%Material= 0.47 Clearance: 0.0235 0.0376

Hole/Feature Size: 0.1637 Clearance Hole/Feature Size: 0.2107 0.2389

Percentage Per Side= 12.00%Clearance: 0.0564

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified

personnel before use for tool design.

GOTO INDEX

CLEARENCE

Page 31

10.0% 12.0% 15.0% 18.0%0.0470 0.0564 0.0705 0.08460.2577 0.2765 0.3047 0.3329

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified

SCREW STRENTH

Page 32

Screw Strength

MINOR DIAMETER OF SCREW= 0.438 INCHESRESULTANT AREA OF SCREW 0.1503

SCREW MATERIAL TENSILE STRENGTH= 10,000 PSISCREW HOLDING POWER 1,503 LBS

NUMBER OF SCREWS= 10.00TOTAL HOLDING POWER 15,033 LBS

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before

use for tool design.

GOTO INDEX

SCREW STRENTH

Page 33

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before

use for tool design.

WEIGHT CALCULATION

Page 34

LENGTH WIDTH HEIGHT DENSITY1.000 1.000 1.000 0.284

AREA (sq. in.) THICKNESS Density36.700 0.500 0.284



GOTO INDEX

WEIGHT CALCULATION

Page 35

Weight0.284

Weight5.2114



SPOT DRILL DEPTH

Page 36

Spot Drill Depth Calculations For CNC

STD DRILL SPOT DRILLDIA 0.1250 DIA 0.1250RAD 0.0625 RAD 0.0625POINT EXTENSION 0.0376 POINT EXTENSION 0.0361

STD DRILL SPOT DRILLOVERAGE 0.0312 OVERAGE 0.0312BASE DIA 0.1250 BASE DIA 0.1250FINAL DIAMETER 0.1562 FINAL DIAMETER 0.1562RAD 0.0781 RAD 0.0781POINT EXTENSION 0.0469 POINT EXTENSION 0.0451

FACTORS118 POINT DIVIDE BY 3.3



GOTO INDEX

DEPTH OF CUT

Page 37

PL 360 (STANDARD MACHINE) 5.5/7.5kW SPINDLE MOTOR

CALCULATION FOR MAXIMUM DEPTH OF CUT FOR GIVEN MOTOR POWER

FORMULA P = (Pz x V) / (102 x 60)

DEFINITION

P - POWER (Kw)Pz - CUTTING FORCE (N-m)V - CUTTING SPEED (m/min)

FORMULA Pz = Ks x f x d x Kr x Kw x Kv

DEFINITION

Ks - SPECIFIC CUTTING RESISTANCEf - FEED (mm/rev)d - DEPTH OF CUT (mm)Kr - CORRECTION FACTOR FOR RAKE ANGLEKw - CORRECTION FACTOR FOR WEARKv - CORRECTION FACTOR FOR CUTTING SPEED

FOR EXAMPLETO CALCULATE MAXIMUM DEPTH FOR CUT FOR GIVEN MATERIAL AND POWER MOTORMATERIAL SPEC. - STEEL-S43CHARDNESS - 180 BHN TENSILE STRENGTH - 62 kg/mm sq

FORMULA Pz = Ks x f x d x Kr x Kw x Kv

Ks = 180 kg/mm SQf = 0.1d = ?Kr = 1.275 Kw = 1.3Kv = 1

Pz = 180 x 0.1 x d x 1.275 x 1.3 x 1

Pz = 29.835 x d

FORMULA P = (Pz x V) / (102 x 60)

DEFINITION

P - POWER (Kw)Pz - CUTTING FORCE (N-m)V - CUTTING SPEED (m/min)

5.5=( (29.835 x d )X(250) ) /( 102 x 60 )

FOR Kr, Kw, Ks & Kv Ref. HMT PRODUCTION TECHNOLOGY BOOK (page No. 87 to 91)

DEPTH OF CUT

Page 38

d=4.5mm

DEPTH OF CUT

Page 39

GOTO INDEX

MACHINE (kw) CALCULATION

Page 40

FEED

5.5 Steel 180 0.8 0.1 250 1.275 1.37.5 Steel 180 0.8 0.3 250 1.275 1.39 Steel 180 0.8 0.1 250 1.275 1.311 Steel 180 0.8 0.3 250 1.275 1.315 Steel 180 0.8 0.1 250 1.275 1.3

18.5 Steel 150 1.2 0.05 180 1.275 1.322 Steel 180 0.8 0.1 250 1.275 1.326 Steel 180 0.8 0.3 250 1.275 1.337 Steel 180 0.8 0.1 250 1.275 1.337 Steel 180 0.8 0.3 250 1.275 1.3

MOTOR POWER kW

MATERIAL

SPECIFIC

CUTTING

FORCE

TOOL RADIUS mm

CUTTING

SPEED

CORRECTION FACTOR FOR WEAR

CORRECTION FACTOR FOR RAKE

ANGLE

GOTO INDEX

MACHINE (kw) CALCULATION

Page 41

1 4.51 112.82 1.56251 2.05 153.85 14.06251 7.38 184.62 1.56251 3.01 225.64 14.06251 12.31 307.69 1.56251 50.60 455.38 0.2604166666671 18.05 451.28 1.56251 7.11 533.33 14.06251 30.36 758.97 1.56251 10.12 758.97 14.0625

CORRECTION FACTOR FOR

CUTTING SPEED

DEPTH OF CUT

mm

METAL REMOVAL cm3/min

SURFACE ROUGHNESS IN Ra

BASIC SIZE HOLE SHAFT

10 A9 k6

Enter the Basic Size and Tolerance grades


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`

Pleae Enter the Basic Size in mm

Please select the Tolerance grade

for Hole

Please select the Tolerance grade

for Shaft

`

HOLE SHAFT316 10

10 280 10 1

315

270

#INDEX

Maximum Clearance/Interferance (Microns)

Minimum Clearance/Interferance (Microns)



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Engineering Calculator