INDEX

INDEX
SURFACE 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.

Page 1

INDEX

INDEX
SPRING PRESURE
CUTTING FORCE
TOLERANCE
THREADING
AIR CYLINDER FORTCE
BEND VARIABLE

#POWER & TORQUE

pplied for reference purposes only. The author

se or engineering based on using this calculator.
be verified by qualified personnel before use for
tool design.

Page 2

INDEX

SCREW STRENTH
WEIGHT CALCULATION
SPOT DRILL DEPTH
DEPTH OF CUT
MACHINE POWER(kw)
THREAD DEPTH CALCULATION
Powered by
SENKAMS SOLUTIONS
LTD.,

Page 3

THREAD DEPTH CALCULATION

THREAD DEPTH CALCULATION

INPUT DETAILS
Thread pitch (mm)
Thread depth (ap)
No. of passes (nap)

GOTO INDEX
1.5
0.940
2

RESULTS
1st pass, radial infeed
2nd pass, radial infeed
3rd pass, radial infeed
4th pass, radial infeed
5th pass, radial infeed
6th pass, radial infeed
7th pass, radial infeed
8th pass, radial infeed
9th pass, radial infeed
10th pass, radial infeed
11th pass, radial infeed
12th pass, radial infeed
13th pass, radial infeed
14th pass, radial infeed
15th pass, radial infeed
16th pass, radial infeed
17th pass, radial infeed
18th pass, radial infeed
19th pass, radial infeed
20th pass, radial infeed
21st pass, radial infeed
22nd pass, radial infeed
23rd pass, radial infeed
24th pass, radial infeed
25th pass, radial infeed
26th pass, radial infeed
27th pass, radial infeed
28th pass, radial infeed

0.515
0.425

Page 4

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

THREAD DEPTH CALCULATION

29th pass, radial infeed

30th pass, radial infeed
31st pass, radial infeed
32nd pass, radial infeed
33rd pass, radial infeed
34th pass, radial infeed
35th pass, radial infeed
36th pass, radial infeed
37th pass, radial infeed
38th pass, radial infeed
39th pass, radial infeed
40th pass, radial infeed
41st pass, radial infeed
42nd pass, radial infeed
43rd pass, radial infeed
44th pass, radial infeed
45th pass, radial infeed
46th pass, radial infeed
47th pass, radial infeed
48th pass, radial infeed
49th pass, radial infeed
50th pass, radial infeed

Page 5

THREAD DEPTH CALCULATION

red 2 passes.
red 50 passes.

Page 6

THREAD DEPTH CALCULATION

Page 7

SURFACE FINISH

Surface Finish Rmax=(fn/8*r)*1000

Feed (fn)
Tool nose radius-r
Ra (normal insert)
Ra (wiper insert)
Surface Finish (feed calculation)
Ra
Tool nose radius-r
Feed (fn)
GOTO INDEX

Page 8

SURFACE FINISH

sh Rmax=(fn/8*r)*1000
0.2
0.4

12.500
6.250

nish (feed calculation)

6.3
0.8

0.201

Page 9

SURFACE FINISH

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

Page 10

QTY CHECK

QUANTITY CHECK

Working days/Month
working hors/shift
Number of shift
Cycle time / comp.
Total hrs/ day
Total hrs/ Month
Minutes/Month
Qty / Month
GOTO INDEX

Page 11

30 days
5.0 hrs
1
5 minutes
5
150
9000

1800 nos

CYCLE TIME CHECK

CYCLE TIME CHECK

Working days/Month
working hors/shift
Number of shift
Qty / Month
Total hrs/ day
Total hrs/ Month
minutes/Month
Cycle time / comp.
GOTO INDEX

Page 12

CYCLE TIME CHECK

CLE TIME CHECK

30 days
7 hrs
2
10 nos
13
390
23400

2340 min
140400 seconds

Page 13

CUTTING SPEED

CUTTING SPEED
Dia. of component
Spindle RPM
Feed (Fn)-mm/rev
Cutting speed (Vc)
Feed (Fn)-mm/min
Spindle RPM
Dia. of component
Cutting speed (Vc)
Spindle RPM
GOTO INDEX

Page 14

CUTTING SPEED

UTTING SPEED
50.0
1000
0.2 mm/rev

Vc=157.08
mm/min=200.00

Spindle RPM
20.0
Vc=120.00

1909.859

Page 15

POWER CALCULATION

POWER CALCULATION
CUTTING SPEED, V m/min
FEED RATE, f mm/rev
DEPTH OF CUT, d mm
POWER CONSTANT, Kp
FEED FACTOR FOR POWER CONSTANTS, C
TOOL WEAR FACTOR, W
MACHINE TOOL EFFICIENCY FACTOR, E
METAL REMOVAL RATE , Q cm/s
POWER AT THE CUTTING TOOL, Pc kW
POWER AT THE MOTOR, Pm kW

GOTO INDEX

Page 16

POWER CALCULATION

N
180
0.5
5
1.69
1.3
0.94
0.8
7.50
15.49
19.36

Page 17

POWER & TORQUE

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 Speed
Cutting Dia mm Vc ( m/min )
440
200
80
160
80
160
80
160

Feed
( mm/
rev )

DP-mm
0.4
0.3
0.3
0.3

3
5
5
5

Specific
Cutting
Energy
Power Req
KG /mm2
Efficiency KW
250
0.8
12.5
250
0.8
12.5
250
0.8
12.5
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
Ps for Cat iron

250 kg /mm2
210 Kg/mm2

Page 18

POWER & TORQUE

#INDEX

Page 19

POWER & TORQUE

Rpm
144.7596989
636.942675159
636.942675159
636.942675159

Req
Cutting
Torque
Available Torque
Force kg NM
100%
300
825
573
375
187.5
179.922
375
187.5
179.922
375
187.5
179.922

Available
Torque 30
min
1055.542
239.896
239.896
239.896

``

Page 20

POWER & TORQUE

Page 21

SPRING PRESURE

Spring Pressure Calculator

Free Length of Spring=
Spring Force / .100"=
Preload=
Travel=
Total Travel:
% Compression:
Force / spring:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY EXTRA HEAVY DUTY

2.000
2.000
2.000
2.000
20
66
154
197
0.125
0.125
0.125
0.125
0.125
0.125
0.125
0.125
0.250
13%
50

0.250
13%
165

0.250
13%
385

0.250
13%
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 e
figures shown here should be verified by qualified personnel before use for t

GOTO INDEX

Page 22

SPRING PRESURE

TONS
245

LBS
490000

19600

no risk for improper use or engineering based on using this calculator. All
d personnel before use for tool design.

Page 23

CUTTING FORCE

Cutting Parameters
TOOL NUMBER
PART NUMBER

INPUT DATA
1
2

Cut Length= 25.000

Stock Thickness= 0.079
Ultimate Shear Strength= 40,000

Cutting Force Required

Mild Steel
25.000
0.079
35,000

Semi-hard Mild
25.000
0.079
55,000

69,125
35

108,625
54

RESULT

LBS: 79,000
TONS: 40

Stripping Force Required

8%
5%
3%

6,320
3,950
2,370

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

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

GOTO INDEX

Page 24

CUTTING FORCE

Mild Stainless
25.000
0.079
80,000

Tough Stainless
25.000
0.079
120,000

158,000
79

237,000
119

no risk for improper use or engineering based on

d personnel before use for tool design.

Page 25

TOLERANCE

Tolerance Transformation
DEVIATION TOLERANCE
Plus= 2.00
Nominal= 100.00
Minus= 1.00

SYMETRIC TOLERANCE
Nominal 101.50 1.50

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

Page 26

THREADING

Thread Calculators
Finds useful thread data.

ENGLISH TAP DRILL

OUTSIDE DIA : 0.500
%THREAD : 0.75
PITCH (THD / INCH) : 13.00
TAP DRILL =

METRIC TAP DRILL

OUTSIDE DIA :
%THREAD :
METRIC PITCH :
TAP DRILL :

16.00 MM
75.00
1.00 MM
15.03 MM

0.592

NUMBER THREADS
THREAD # : 7
MAJOR DIAMETER : 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

Page 27

AIR CYLINDER FORCE

Air Cylinder Forces & Inputs

INPUT BORE DIA
RESULTING AREA=
FORCE PER 10 PSI=

2.000
3.142
31.42

INCHES
SQUARE INCHES
POUNDS OF FORCE

INPUT LINE PRESSURE

FORCE=

50
157.08

PSI
POUNDS

INPUT LINE PRESSURE

FORCE=

70
219.91

PSI
POUNDS

INPUT LINE PRESSURE

FORCE=

100
314.16

PSI
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

Page 28

AIR CYLINDER FORCE

r assumes no risk for

hown here should be
gn.

Page 29

BEND VARIABLE
Bend Variables
Set Radius Given Form Radius
Form Radius= R .032
Stock Thickness= .0470
Degrees of Arc= 90.00
Neural Axis (%)= 5%
RADIUS OF NEUTRAL AXIS: R .034
BEND DEDUCTION: .0532
SET RADIUS (1.35 X STOCK): R .097

1.3505968

Form Radius Given Set Radius

(REFERENCE - BASED ON 8% THINNING)
Set (Outside) Radius= R .060
Stock Thickness= .0375
Degrees of Arc= 90.00
Neural Axis (%)= 42%
RADIUS OF NEUTRAL AXIS: R .420
BEND DEDUCTION: .6598
Form (inside) RADIUS: R .019

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

GOTO INDEX

Page 30

BEND VARIABLE

r assumes no risk for improper use or engineering

d by qualified personnel before use for tool design.

Page 31

CLEARENCE

Clearance
Material= 0.47
Hole/Feature Size: 0.1637

Percentage Per Side=

Clearance:

Clearance:
Clearance Hole/Feature Size:

5.0%
0.0235
0.2107

8.0%
0.0376
0.2389

12.00%
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

Page 32

CLEARENCE

10.0%
0.0470
0.2577

12.0%
0.0564
0.2765

15.0%
0.0705
0.3047

18.0%
0.0846
0.3329

no risk for improper use

verified by qualified

Page 33

SCREW STRENTH

Screw Strength
MINOR DIAMETER OF SCREW=
RESULTANT AREA OF SCREW
SCREW MATERIAL TENSILE STRENGTH=
SCREW HOLDING POWER
NUMBER OF SCREWS=
TOTAL HOLDING POWER

0.438 INCHES
0.1503
10,000 PSI
1,503 LBS
10.00
15,033 LBS

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

GOTO INDEX

Page 34

SCREW STRENTH

y. The author assumes no risk for improper use or

here should be verified by qualified personnel before
esign.

Page 35

WEIGHT CALCULATION

LENGTH
1.000

WIDTH
1.000

AREA (sq. in.)

36.700

THICKNESS
0.500

HEIGHT DENSITY
1.000
0.284

Density
0.284

Note: This calculator is supplied for reference purposes only. The autho
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

Page 36

WEIGHT CALCULATION

Weight
0.284

Weight
5.2114

purposes only. The author

ering based on using this
be verified by qualified
ol design.

Page 37

SPOT DRILL DEPTH

Spot Drill Depth Calculations For CNC

STD DRILL
DIA
RAD
POINT EXTENSION

0.1250
0.0625
0.0376

SPOT DRILL
DIA
RAD
POINT EXTENSION

0.1250
0.0625
0.0361

STD DRILL
OVERAGE
BASE DIA
FINAL DIAMETER
RAD
POINT EXTENSION

0.0312
0.1250
0.1562
0.0781
0.0469

SPOT DRILL
OVERAGE
BASE DIA
FINAL DIAMETER
RAD
POINT EXTENSION

0.0312
0.1250
0.1562
0.0781
0.0451

118 POINT

FACTORS
DIVIDE BY 3.3

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

Page 38

DEPTH OF CUT
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 RESISTANCE
f - FEED (mm/rev)
d - DEPTH OF CUT (mm)
Kr - CORRECTION FACTOR FOR RAKE ANGLE
Kw - CORRECTION FACTOR FOR WEAR
Kv - CORRECTION FACTOR FOR CUTTING SPEED

FOR EXAMPLE
TO CALCULATE MAXIMUM DEPTH FOR CUT FOR GIVEN MATERIAL AND POWER MOTOR
MATERIAL SPEC. - STEEL-S43C
HARDNESS
- 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 SQ
f = 0.1
d =?
Kr = 1.275
Kw = 1.3
Kv = 1

FOR Kr, Kw, Ks & Kv Ref. HMT PRODUCTION

TECHNOLOGY BOOK (page No. 87 to 91)

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

Pz =
FORMULA

29.835 x d

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 )

Page 39

DEPTH OF CUT
d=4.5mm

Page 40

DEPTH OF CUT

GOTO INDEX

Page 41

DEPTH OF CUT

Page 42

MACHINE (kw) CALCULATION

SPECIFI
CORRECTIO
C
TOOL
CUTTIN CORRECTIO
MOTOR
MATERIA
N FACTOR
CUTTIN RADIU FEED
G
N FACTOR
POWER kW
L
FOR RAKE
G
S mm
SPEED FOR WEAR
ANGLE
FORCE

5.5
7.5
9
11
15
18.5
22
26
37
37

Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel

180
180
180
180
180
150
180
180
180
180

0.8
0.8
0.8
0.8
0.8
1.2
0.8
0.8
0.8
0.8

0.1
0.3
0.1
0.3
0.1
0.05
0.1
0.3
0.1
0.3

GOTO INDEX

Page 43

250
250
250
250
250
180
250
250
250
250

1.275
1.275
1.275
1.275
1.275
1.275
1.275
1.275
1.275
1.275

1.3
1.3
1.3
1.3
1.3
1.3
1.3
1.3
1.3
1.3

MACHINE (kw) CALCULATION

CORRECTION
DEPTH
METAL
FACTOR FOR
SURFACE
OF CUT REMOVAL
CUTTING
ROUGHNESS IN Ra
mm
cm3/min
SPEED

1
1
1
1
1
1
1
1
1
1

4.51
2.05
7.38
3.01
12.31
50.60
18.05
7.11
30.36
10.12

112.82
153.85
184.62
225.64
307.69
455.38
451.28
533.33
758.97
758.97

1.5625
14.0625
1.5625
14.0625
1.5625
0.2604166667
1.5625
14.0625
1.5625
14.0625

Page 44

Pleae Enter the Basic Size

in mm

BASIC SIZE

Please select the

Tolerance grade
for Hole

Please select the

Tolerance grade
for Shaft

HOLE SHAFT
`

23

A9

Enter
Enterthe
theBasic
BasicSize
Size
and
andTolerance
Tolerancegrades
grades

k6

`
`

#INDEX

HOLE
352

`
`
`

SHAFT

23

300

15
2

23

Maximum Clearance/
Interferance (Microns)

350

Minimum Clearance/
Interferance (Microns)

285