Student Material 001: Machine Tool Fundamentals Quick Reference¶
Material ID: U8M1-MAT-001 Purpose: Quick reference for speed/feed calculations, cutting parameters, and workholding selection
Speed Calculation Formulas¶
Lathe RPM = (SFM × 3.82) / Workpiece Diameter (inches)
Mill RPM = (SFM × 3.82) / Cutter Diameter (inches)
Mill Feed Rate (IPM) = RPM × Number of Teeth × Feed per Tooth (IPT)
Material Removal Rate (Lathe) = 12 × SFM × DOC × Feed (IPR)
Cutting Speed Reference (SFM)¶
| Material | HSS Tool | Carbide Tool |
|---|---|---|
| Mild Steel (1018, 1020) | 80-100 | 300-500 |
| Medium Carbon (1045) | 70-90 | 250-400 |
| Alloy Steel (4140) | 60-80 | 200-350 |
| Stainless (304, 316) | 40-60 | 150-250 |
| Tool Steel (O1, A2) | 40-60 | 150-250 |
| Aluminum (6061, 7075) | 200-300 | 800-1500 |
| Brass | 150-250 | 500-800 |
| Bronze | 100-150 | 350-600 |
| Cast Iron (gray) | 50-80 | 250-400 |
| Plastic (Delrin, HDPE) | 200-400 | 500-1000 |
Feed Rate Reference¶
Lathe (Inches Per Revolution)¶
| Operation | HSS | Carbide |
|---|---|---|
| Roughing | 0.005-0.015 | 0.008-0.020 |
| Finishing | 0.002-0.005 | 0.003-0.008 |
| Threading | Determined by thread pitch | Same |
| Parting | 0.002-0.005 | 0.003-0.006 |
Mill (Inches Per Tooth)¶
| Material | HSS End Mill | Carbide End Mill |
|---|---|---|
| Mild Steel | 0.002-0.005 | 0.003-0.008 |
| Aluminum | 0.005-0.010 | 0.005-0.015 |
| Brass | 0.003-0.008 | 0.005-0.010 |
| Stainless | 0.001-0.003 | 0.002-0.005 |
Depth of Cut Reference¶
| Operation | Roughing | Finishing |
|---|---|---|
| Lathe turning | 0.050-0.150" | 0.005-0.020" |
| Lathe facing | 0.030-0.100" | 0.005-0.015" |
| Mill end milling | 0.050-0.250" | 0.010-0.030" |
| Mill face milling | 0.030-0.100" | 0.005-0.020" |
Workholding Selection Guide¶
Lathe¶
| Workpiece | Recommended | Accuracy (TIR) |
|---|---|---|
| Round stock, general | Three-jaw chuck | 0.003-0.005" |
| Round stock, precision | Four-jaw or collet | <0.001" |
| Hex stock | Three-jaw chuck | 0.003-0.005" |
| Square/irregular | Four-jaw chuck | <0.001" (after indicating) |
| Long stock (>3× diameter) | Chuck + tailstock center | N/A |
| Very long stock | Between centers | Excellent concentricity |
Mill¶
| Workpiece | Recommended | Notes |
|---|---|---|
| Rectangular block | Machine vise + parallels | Most common setup |
| Large/irregular | T-slot clamps | Minimum 2 clamps |
| Round stock | V-blocks in vise | Or collet block |
| Thin stock | Vise with parallels, light grip | Risk of deflection |
| Angular work | Angle plate or sine bar | Precision angles |
Chuck Key Reminder¶
REMOVE THE CHUCK KEY IMMEDIATELY AFTER EVERY USE. Never leave it in the chuck. Not even for a second.
Last Updated: 2026-03-19