MachineCalcs

Machining Calculators

Dial in speeds, feeds, setup and manufacturing estimates: SFM↔RPM, chip load, radial chip thinning compensation for HSM stepovers, CNC feed rates, milling, turning and drilling power, drilling feed/time, peck drilling cycle planning, G76 threading pass ladders at constant chip area, cutoff/grooving cycle time under constant surface speed, end-mill helical ramp entry planning, theoretical surface finish, end-mill stickout deflection, tap-drill and thread sizing with ASME B1.1 class 2A/2B thread limits and three-wire measurement, injection molding shot size and clamp force, tapping and thread-mill feeds, sine-bar angles, arc radius from chord and rise, knurl tracking diameters, ball-nose stepover, countersink depth and drill-point allowance, tool runout vs chip load, bandsaw cut time, grinding wheel speed against the marked max RPM with the cylindrical q ratio and grinding contact length, and coolant mix/refractometer concentration — backed by cutting-speed and drill-size charts.

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Chip load for end mills Feed per tooth, feed rate, RPM and flute count conversion for milling. Peck drilling cycle Peck count, programmed depth and G83/G73-style retract overhead. Thread mill feed compensation Tool-centre feed from cutting-edge feed for internal and external helical interpolation. Tapping feed by thread pitch Rigid-tapping feed rate from spindle RPM and thread pitch; feed per rev equals pitch. Sine bar angle setup Gauge-block stack from angle or angle from stack height. Countersink diameter depth Conical countersink plunge depth and chamfer width from hole and rim diameters. Spot drill depth allowance Drill-point cone length and total blind-hole depth from diameter and included angle. Drilling feed and point allowance Feed per rev, RPM, drill point allowance and cutting feed time. Drilling horsepower Drill-area MRR, spindle power and torque from feed and kc. Helical ramp entry End-mill ramp pitch, turns, path length, entry time and chip load. End mill deflection Stickout, flute length, radial force and stiffness factor to deflection and stress. Dovetail over pins Male and female dovetail inspection measurements over or between pins. Boring bar deflection Static tool deflection, bending stress and L/D overhang ratio.

Workflow suites using Machining

Multi-tool paths for jobs that cross category boundaries.

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Primary Thread Cutting & Measurement Run a thread from print to gauge: size the hole or blank, hold the ASME B1.1 2A/2B limits, plan the cutting passes and verify the pitch diameter over wires.

All Machining calculators

Surface Feet per Minute Cutting speed (SFM / m·min) and diameter to spindle RPM, with cutting speeds by material. Cutting Speed Convert cutting speed to spindle RPM, or calculate actual SFM / m·min from RPM and diameter. Bore & Stroke Engine displacement (cc / L / ci) and bore/stroke ratio from bore, stroke and cylinders. Tap Drill Size Tap drill diameter for any metric or unified thread at your chosen % thread engagement. Unified Thread Limits (2A/2B) ASME B1.1 limits from diameter and TPI: 2A allowance, major and pitch diameter limits, 2B pitch and minor limits — table-exact, any UNS pitch. Keyway Dimension Standard parallel key & keyway dimensions for a shaft per DIN 6885-1. CNC Speeds and Feeds Spindle RPM, feed rate, feed per rev and material removal rate from material, tool, flutes and chip load. Milling Horsepower Milling material removal rate, cutting power, spindle horsepower, torque and chip load from cut engagement and feed. Turning Horsepower Turning material removal rate, cutting power, spindle horsepower, torque and cutting force from speed, feed and depth. Drilling Horsepower Drilling material removal rate, cutting power, spindle horsepower and torque from drill diameter, RPM, feed and kc. Machining Time Estimate CNC feed time, cycle time, batch time and parts per hour from toolpath length, feed rate, RPM, chip load and passes. Machine Shop Rate Estimate a loaded shop hourly rate from labor wage, burden, monthly overhead, billable utilization and target margin. Machining Cost Estimate CNC part cost from material, setup, cycle time, shop rate, tooling, secondary work and markup. Injection Molding Shot Size Estimate shot weight, barrel utilization, machine capacity range and clamp force from part weight, cavities, runner weight and projected area. Chip Load Chip load (feed per tooth) ↔ milling feed rate from RPM and flutes — Vf = fz·Z·n. Radial Chip Thinning Compensated feed per tooth and table feed for light stepovers: target chip ÷ √(1−(1−2ae/D)²), with thinning factor and engagement angle. G76 Threading Infeed Constant-chip-area threading passes: cumulative depth total × √(n/N) with the full pass ladder, first/last depths and a rubbing check. Coolant Mix Ratio Concentrate and water for a fill at target %, sump correction from refractometer reading × factor, and the expected Brix at target. Grinding Wheel Speed Wheel surface speed vs the marked max RPM (never exceeded), plus cylindrical work speed and the 60-100 q ratio. Knurl Blank Diameter Nearest tracking diameter from TPI, diametral pitch or linear pitch: whole teeth around the work, the correction to turn and finished OD. Arc Radius Radius from chord and height (r = c²/8h + h/2) or sagitta from radius and chord, with diameter, included angle and arc length. Cutoff & Grooving Cycle Time Parting/plunge time at constant surface speed with the RPM clamp: CSS and clamped phases, clamp diameter, and time saved vs constant RPM. Grinding Contact Length Equivalent diameter for surface/OD/ID grinding and the arc of contact lc = √(ae·De) — why bores need softer wheels than shafts. Tool Runout vs Chip Load Max/min feed per tooth from measured TIR (f_z ± TIR), runout share vs the ~10% guideline, allowable runout and the single-tooth flag. Bandsaw Cut Time Time per cut from section area and the blade chart’s area rate (t = A ÷ Q), round or rectangular stock, bundles, and feed-on cuts per hour. Surface Finish Theoretical turning Ra & Rz from feed and nose radius — or the max feed for a target finish. Surface Finish Ra/Rz Converter Approximate conversion between Ra, Rz, RMS and ISO N roughness grade. Tapping Feed Rate Tapping feed rate Vf = spindle RPM × thread pitch; the feed per rev equals the pitch. Drilling Feed Rate Drilling feed rate, point allowance, cycle time, cutting speed and material removal rate. Peck Drilling Plan peck count, programmed depth, feed time and G83/G73-style retract overhead. Thread Mill Feed Compensate thread-mill feed for helical interpolation — tool-centre from cutting-edge feed. Helical Ramp Entry Plan end-mill helical ramp pitch, turns, path length, entry time and ramp feed from angle, depth and bore or tool-center path diameter. Sine Bar Gauge-block stack for a sine bar set to an angle (or the angle from a stack) — h = L·sin θ. Taper Per Foot Taper per foot, taper angle, compound angle, taper ratio and lathe tailstock setover from two diameters and taper length. Ball Nose Stepover Scallop height between parallel ball-nose passes — or the stepover for a target finish. End Mill Deflection End-mill stickout deflection, stress, L/D ratio and required diameter from radial force, flute length and stiffness factor. Boring Bar Deflection Static tool tip deflection, bending stress, L/D overhang ratio and required diameter for boring bars or cutter stickout. Countersink Depth Plunge depth and chamfer width of a conical countersink from angle, rim and hole diameter. Dividing Head Indexing Crank turns and index-plate holes from a division count or DMS angle — B&S plates or custom circle, any worm ratio. Lathe Change Gear Screw-cutting gear trains for any pitch on any leadscrew — exact via 127, or closest train with ppm error. Drill Point Length Drill tip allowance and total blind-hole depth from diameter, point angle and full-diameter depth. Dovetail Over-pin / between-pin measurement for inspecting a male or female dovetail slide.

This cluster runs the actual shop-floor and manufacturing math rather than a generic physics widget. The CNC speeds and feeds calculator takes spindle speed from cutting speed and tool diameter, n = Vc/(π·D), then derives feed rate from chip load and flute count, Vf = fz·Z·n, and reports the material removal rate Q = aₚ·aₑ·Vf — the numbers that decide tool life, feed time and spindle load. If you only need to convert a target surface speed, the SFM-to-RPM calculator handles RPM = (SFM·12)/(π·D) for both turning (work diameter) and milling or drilling (tool diameter).

It is built for machinists, CNC programmers, estimators and manufacturing engineers who want a defensible starting point, not a guess. Each tool shows its formula, and feed work is backed by the cutting-speed chart by material so your Vc is grounded in published data. For milling, the chip load calculator solves fz ↔ Vf in either direction, and the milling horsepower calculator carries width of cut, depth of cut, feed rate and specific cutting force into MRR, spindle power and torque. The helical ramp entry calculator then turns bore or tool-center path diameter, ramp angle, depth and feed into helix pitch, turns, path length, entry time and ramp chip load before the move goes into CAM. For lathe work, the turning horsepower calculator uses work diameter, cutting speed, feed per revolution, depth of cut and kc to estimate turning MRR, spindle power, torque and cutting force. For holemaking, the drilling feed rate calculator turns RPM and feed per revolution into cutting feed, drill-point allowance, cycle time and material removal rate, while the peck drilling calculator compares G83-style full-retract and G73-style chip-break overhead for deep holes. The drilling horsepower calculator checks drill-area MRR, spindle power and torque.

After the process numbers are believable, the machining time calculator converts cutting length, approach, overtravel, passes and feed rate into feed time, cycle time, batch time and parts per hour. Then the machine shop rate calculator derives a loaded hourly rate from labor, overhead, utilization and target margin before the machining cost calculator converts material, scrap, setup time, cycle time, shop rate, tooling, secondary work and markup into direct cost, quoted price each and batch total. For molded plastic parts, the injection molding shot size calculator checks part weight, runner weight, cavity count, machine shot utilization and projected-area clamp force before a press is selected. Unlike tool-vendor wizards that gate a quote, MachineCalcs runs in metric and imperial and pairs speeds-and-feeds with setup math — tap drill, sine bar, ball-nose stepover, end mill stickout deflection, boring bar and tool deflection, countersink depth and drill point length for blind-hole allowances.

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