Calculation of Cutting Modes in Turning, Drilling, Milling and Thread Cutting

Calculation of Cutting Modes in Turning, Drilling, Milling and Thread Cutting

This file is a teaching-methodological manual (practicum) in Russian entitled “Calculation of Cutting Conditions for Turning, Drilling, Milling and Thread Cutting.” The manual is a supplement to the educational-methodological complex for the subject “Technology of Industrial Production.”

The manual includes 12 sections, Appendices A–Zh, answers and model solutions, and a final checklist. At the beginning, it provides an abstract, explanatory note, goals and objectives, target audience, requirements for initial data, rules for working with formulas and units of measurement, and a general calculation algorithm (20 steps). Then follow the sections:

Section I. Calculation Fundamentals — the physical meaning of the cutting mode, speed, rotational frequency, feed (per revolution, per tooth, minute feed), depth, milling width, working stroke length, main and piece time, tool life, cutting force and power, rigidity of the machine–fixture–tool–workpiece system, and verification against the machine tool data sheet.

Section II. Turning — features, types of operations, calculation procedure, worked examples (rough/finish turning, boring, face turning), calculation card form, and review questions.

Section III. Drilling and Hole Machining — drilling, drilling out/enlarging, countersinking, reaming, deep holes, examples, and comparison of operations.

Section IV. Milling — types of milling cutters, milling schemes, formulas, examples (face, end, cylindrical), and calculation card.

Section V. Thread Cutting — with taps, dies, thread-cutting tools, and rolling; features, examples, and multi-start threads.

Section VI. Verification against Production Constraints — list of constraints, procedure for overload, and an example of mode correction.

Section VII. Machine (Main) and Piece Time — structure of the time norm, example calculation of Тшт and Тшк (piece time and piece-calculation time), productivity analysis, and typical errors.

Section VIII. Typical Errors — a table of errors and ways to avoid them.

Section IX. Professional Situations — 8 situations close to real equipment setup.

Section X. Spreadsheets and Computer Verification — Excel templates and a Python example.

Section XI. Individual Variants — assignment variants for Practical Works No. 2–5.

Section XII. Self-Check — test, problems, and self-assessment criteria.

Appendices — designations and units, conventional training range of frequencies, summary of formulas, report form, operation chart, and references.

Answers and Model Solutions — test keys, problem solutions, model answers for variants, and comments.

Additional information:

Format — PDF, volume — 100 pages.

The manual strictly distinguishes between types of values (educational approximate/indicative, reference, normative, machine-data-sheet, and conditional values assigned for the variant) and requires their origin to be indicated. All calculations are performed in a calculation-and-graphic form, without access to metal-cutting equipment. It is emphasized that the results are educational and do not replace practical training on machine tools. A unified algorithm, worked examples, and formatting templates are provided, which allows the student to immediately begin their own variant.