CNC Job Setup Sheet Generator - Speeds, Feeds & Chipload Verification

How It Works

1. Enter Job Information

   Part number, work order, material, operation type, and coolant. Material presets are local starting rows, not manufacturer approval.

2. Add Cutting Tools

   Up to 8 tools: tool number, description, diameter, effective teeth or lips, SFM, feed input, and turning nose radius.

3. Review Starting Parameters

   RPM, feed IPM, feed IPR, local feed range, and turning-only theoretical Ra are calculated from the entered geometry.

4. Check Local Feed Warnings

   Green/amber/red indicators flag values outside the app local heuristic range for further manufacturer and shop review.

5. Print or Export

   Preview a shop-format planning sheet with sign-off lines. Export as PDF for review and prove-out notes.

Built For

• CNC setup operators documenting starting values before prove-out
• Shop supervisors reviewing workholding, coolant, and first-article notes
• Job shop machinists managing repeat part numbers with known source gaps visible
• Training programs teaching setup planning and source boundaries
• Quality teams using setup sheets as shop records after qualified review
• Shops transitioning from hand-written setup cards to digital planning documentation

Features & Capabilities

Dynamic Tool Table

Up to 8 tools with milling, drilling, or turning planning parameters. Add/remove tools as needed.

RPM and Feed Arithmetic

RPM, feed rate, IPR, and feed input are calculated from SFM and geometry inputs.

Local Feed Check

Color-coded local heuristic check: green, amber, or red for review against tooling data and shop conditions.

Turning Ra Screen

Geometry-only theoretical Ra for turning. Actual finish and inspection acceptance require measurement and review.

Shop Print Format

Job header, material block, tool table, notes, and sign-off lines for setup planning and prove-out records.

PDF Export

Export as branded PDF for machine-side review or source-aware shop records.

Assumptions

• RPM calculated as SFM x 12 / (pi x cutter diameter) per standard machining formula
• Feed rate (IPM) calculated as chip load per tooth x number of flutes x RPM for milling operations
• Feed per revolution (IPR) for turning calculated directly from user input or derived from IPM/RPM
• Theoretical surface finish (Ra) estimated from feed and nose radius using Ra = f^2 / (32 x r)
• Local feed verification ranges are heuristic source-gap rows and are not manufacturer recommendations
• Material presets provide planning SFM starting ranges that require current tooling and shop validation

Limitations

• Does not verify that calculated RPM is within the machine spindle speed range; user must confirm against machine specs
• Feed verification is a local guideline and does not account for specific tool geometry, coating, chip thinning, holder, coolant, or manufacturer recommendations
• Surface finish estimates are theoretical turning geometry screens; actual finish depends on insert geometry, runout, chatter, wear, material, and measurement method
• Maximum 8 tools per setup sheet; complex multi-operation parts may require multiple sheets
• Does not generate tool path or program structure; setup sheet is for parameter documentation only
• Coolant type, flow rate, and delivery method (flood, through-tool, mist) are not calculated

References

1. Sandvik Coromant - Milling, turning, and drilling formulas and definitions (formula context)
2. Kennametal - Feeds and speeds workflow and theoretical turning surface-finish calculator
3. Machinery's Handbook, 32nd Edition - commercial machining reference source pointer
4. Tooling manufacturer catalog or application engineer for selected tool, grade, material, holder, and coolant
5. Machine builder documentation for spindle speed, feed mode, horsepower, torque, holder rating, and safe setup limits
6. Shop quality and safety procedures for first article, inspection, guarding, PPE, and setup review

Frequently Asked Questions