The most expensive confusion in machining
An insert box says 250. A machinist sets the spindle to 250 rpm and ruins a carbide insert on a 20 mm bar, or scraps it instantly on a 200 mm one. The 250 was a CUTTING SPEED — how fast the metal passes the cutting edge — and it has nothing to do with how fast the spindle turns until a diameter has had its say.
— read aloud V equals pi D N. is the cutting speed, the surface speed at the edge, in metres per minute. is the diameter at the cut in millimetres — the workpiece diameter when turning, the cutter diameter when milling. is the spindle speed in revolutions per minute. The bar presents its CIRCUMFERENCE to the edge once per revolution, which is where the comes from, and forgetting it is a factor-of-three error that looks perfectly reasonable on the page.
Which diameter goes in depends on what the machine is doing, and the trap is turning: it is the diameter of the surface BEING CUT, which shrinks with every pass, so a roughing sequence at fixed rpm runs slower and slower in surface terms. That is precisely what a CNC lathe's constant-surface-speed mode exists to fix.
Then the feed. A milling cutter is fed per TOOTH, because each tooth takes its own chip: — v-f equals N z f-z. is the table feed rate in millimetres per minute, the one number the machine is actually programmed in. is the spindle speed in rpm. is the number of effective cutting teeth, a plain count with no units. is the feed per tooth, the chip load, in millimetres per tooth — the one number the cutter's data sheet actually cares about.
A chip load too small is not the safe error. The edge stops cutting and starts rubbing, which work-hardens the surface and burns the tool faster than a heavy cut ever would. Machining is one of the few places where being timid is the expensive choice.