{
    "slug": "material-removal-rate",
    "title": "按主轴功率划分的材料去除率：10 与 20 kW",
    "description": "针对八种常用 CNC 合金，给出 10 与 20 kW 主轴上的受功率限制材料去除率（MRR）对照数据，并附单位切削功率表、已发表车间实测基准与一个完整的切削时间算例。",
    "lang": "zh",
    "tables": [
        {
            "caption": "10 与 20 kW 主轴功率下的粗加工 MRR 上限（受功率限制，计算值）",
            "columns": [
                "材料与状态",
                "采用的 K_p（kW/(cm³/s)）",
                "10 kW 车削（cm³/min）",
                "10 kW 铣削，循环平均（cm³/min）",
                "20 kW 车削（cm³/min）",
                "20 kW 铣削，循环平均（cm³/min）"
            ],
            "rows": [
                {
                    "材料与状态": "Aluminum 6061-T6 (wrought, ~95 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "0.76–0.90",
                    "10 kW 车削（cm³/min）": "425–505",
                    "10 kW 铣削，循环平均（cm³/min）": "340–405",
                    "20 kW 车削（cm³/min）": "850–1,010",
                    "20 kW 铣削，循环平均（cm³/min）": "680–810"
                },
                {
                    "材料与状态": "Aluminum 7075-T6 (wrought, ~150 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "0.76–0.90",
                    "10 kW 车削（cm³/min）": "425–505",
                    "10 kW 铣削，循环平均（cm³/min）": "340–405",
                    "20 kW 车削（cm³/min）": "850–1,010",
                    "20 kW 铣削，循环平均（cm³/min）": "680–810"
                },
                {
                    "材料与状态": "Carbon steel 1045 (190–220 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "1.70–2.32",
                    "10 kW 车削（cm³/min）": "165–225",
                    "10 kW 铣削，循环平均（cm³/min）": "130–180",
                    "20 kW 车削（cm³/min）": "330–450",
                    "20 kW 铣削，循环平均（cm³/min）": "260–360"
                },
                {
                    "材料与状态": "Alloy steel 4140 (Q&T, 280–320 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "2.18–3.29",
                    "10 kW 车削（cm³/min）": "115–175",
                    "10 kW 铣削，循环平均（cm³/min）": "90–140",
                    "20 kW 车削（cm³/min）": "230–350",
                    "20 kW 铣削，循环平均（cm³/min）": "180–280"
                },
                {
                    "材料与状态": "Stainless 304 (annealed, 150–180 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "1.64–2.94",
                    "10 kW 车削（cm³/min）": "130–235",
                    "10 kW 铣削，循环平均（cm³/min）": "105–190",
                    "20 kW 车削（cm³/min）": "260–470",
                    "20 kW 铣削，循环平均（cm³/min）": "210–380"
                },
                {
                    "材料与状态": "Stainless 316 (annealed, 150–180 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "1.64–2.94",
                    "10 kW 车削（cm³/min）": "130–235",
                    "10 kW 铣削，循环平均（cm³/min）": "105–190",
                    "20 kW 车削（cm³/min）": "260–470",
                    "20 kW 铣削，循环平均（cm³/min）": "210–380"
                },
                {
                    "材料与状态": "Titanium Ti-6Al-4V (annealed, 330–350 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "1.65–1.77",
                    "10 kW 车削（cm³/min）": "215–230",
                    "10 kW 铣削，循环平均（cm³/min）": "170–185",
                    "20 kW 车削（cm³/min）": "430–460",
                    "20 kW 铣削，循环平均（cm³/min）": "340–370"
                },
                {
                    "材料与状态": "Brass C36000 (free-cutting, 90–120 HB)",
                    "采用的 K_p（kW/(cm³/s)）": "0.82–1.90",
                    "10 kW 车削（cm³/min）": "200–465",
                    "10 kW 铣削，循环平均（cm³/min）": "160–370",
                    "20 kW 车削（cm³/min）": "400–930",
                    "20 kW 铣削，循环平均（cm³/min）": "320–740"
                }
            ]
        },
        {
            "caption": "10 kW 的 CNC 机床在铝件上能实现多大材料去除率？",
            "columns": [
                "来源",
                "机床 / 案例",
                "材料",
                "MRR（cm³/min）",
                "备注"
            ],
            "rows": [
                {
                    "来源": "S5",
                    "机床 / 案例": "40-taper VMC, stable roughing",
                    "材料": "Carbon steel",
                    "MRR（cm³/min）": "50–100",
                    "备注": "原文为 3–6 in³/min"
                },
                {
                    "来源": "S5",
                    "机床 / 案例": "40-taper VMC, HSM strategy",
                    "材料": "Aluminum",
                    "MRR（cm³/min）": "245–410",
                    "备注": "原文为 15–25 in³/min"
                },
                {
                    "来源": "S5",
                    "机床 / 案例": "50-taper / horizontal",
                    "材料": "Steel",
                    "MRR（cm³/min）": "100–200",
                    "备注": "约为 40 锥度数值的两倍"
                },
                {
                    "来源": "S6",
                    "机床 / 案例": "120 kW, 27,000 rpm (DST Ecospeed)",
                    "材料": "Aluminum 7050",
                    "MRR（cm³/min）": "5,160",
                    "备注": "竞品 PCD 刀具，案例 1"
                },
                {
                    "来源": "S6",
                    "机床 / 案例": "120 kW, 27,000 rpm",
                    "材料": "Aluminum 7050",
                    "MRR（cm³/min）": "7,465",
                    "备注": "RAL90 涂层，同一案例"
                },
                {
                    "来源": "S6",
                    "机床 / 案例": "120 kW, 33,000 rpm (Makino MAG 3.W)",
                    "材料": "Aluminum (cutter diameter 50 mm)",
                    "MRR（cm³/min）": "7,000",
                    "备注": "60 min 去除 420,000 cm³"
                },
                {
                    "来源": "S8",
                    "机床 / 案例": "Bridgeport 2 hp / HAAS 30 hp comparison",
                    "材料": "Aluminum",
                    "MRR（cm³/min）": "165",
                    "备注": "切削功率 1.1–3.0 kW 时为 10.1 in³/min"
                }
            ]
        },
        {
            "caption": "同一台 10 kW 主轴上，304 不锈钢比 6061 慢多少？",
            "columns": [
                "材料",
                "状态",
                "ISO",
                "硬度（HB）",
                "K_p（kW/(cm³/s)）",
                "来源（低 / 高）"
            ],
            "rows": [
                {
                    "材料": "Aluminum 6061-T6",
                    "状态": "wrought, T6",
                    "ISO": "N",
                    "硬度（HB）": "~95",
                    "K_p（kW/(cm³/s)）": "0.76–0.90",
                    "来源（低 / 高）": "S4 / S3"
                },
                {
                    "材料": "Aluminum 7075-T6",
                    "状态": "wrought, T6",
                    "ISO": "N",
                    "硬度（HB）": "~150",
                    "K_p（kW/(cm³/s)）": "0.76–0.90",
                    "来源（低 / 高）": "S4 / S3 — take the upper end for 7075"
                },
                {
                    "材料": "Carbon steel 1045",
                    "状态": "hot-rolled / normalized",
                    "ISO": "P",
                    "硬度（HB）": "190–220",
                    "K_p（kW/(cm³/s)）": "1.70–2.32",
                    "来源（低 / 高）": "S2 (190 HB) / S3 (200–220 HB)"
                },
                {
                    "材料": "Alloy steel 4140",
                    "状态": "quenched and tempered, 28–32 HRC",
                    "ISO": "P",
                    "硬度（HB）": "280–320",
                    "K_p（kW/(cm³/s)）": "2.18–3.29",
                    "来源（低 / 高）": "S3 (280–320 HB) / S4 (220–420 HB upper bound)"
                },
                {
                    "材料": "Stainless 304",
                    "状态": "annealed",
                    "ISO": "M",
                    "硬度（HB）": "150–180",
                    "K_p（kW/(cm³/s)）": "1.64–2.94",
                    "来源（低 / 高）": "S3 (150–175 HB) / S4 (austenitic 150–275 HB)"
                },
                {
                    "材料": "Stainless 316",
                    "状态": "annealed",
                    "ISO": "M",
                    "硬度（HB）": "150–180",
                    "K_p（kW/(cm³/s)）": "1.64–2.94",
                    "来源（低 / 高）": "S3 (150–175 HB) / S4 (austenitic 150–275 HB)"
                },
                {
                    "材料": "Titanium Ti-6Al-4V",
                    "状态": "annealed",
                    "ISO": "S",
                    "硬度（HB）": "330–350",
                    "K_p（kW/(cm³/s)）": "1.65–1.77",
                    "来源（低 / 高）": "S4 (300–360 HB) / S3 (Ti-150 A, 340 HB)"
                },
                {
                    "材料": "Brass C36000",
                    "状态": "leaded free-machining",
                    "ISO": "N",
                    "硬度（HB）": "90–120",
                    "K_p（kW/(cm³/s)）": "0.82–1.90",
                    "来源（低 / 高）": "S3 / S4 — see the conflict register"
                }
            ]
        },
        {
            "caption": "10 kW 机床上加工 4140 钢，MRR 应该按多少规划？",
            "columns": [
                "材料",
                "K_p（kW/(cm³/s)）",
                "刀具处 P_c（kW）",
                "主轴输入 P_spindle（kW）",
                "10 kW 主轴负载（%）"
            ],
            "rows": [
                {
                    "材料": "Aluminum 6061-T6",
                    "K_p（kW/(cm³/s)）": "0.90",
                    "刀具处 P_c（kW）": "1.29",
                    "主轴输入 P_spindle（kW）": "1.5",
                    "10 kW 主轴负载（%）": "15"
                },
                {
                    "材料": "Carbon steel 1045",
                    "K_p（kW/(cm³/s)）": "2.32",
                    "刀具处 P_c（kW）": "3.33",
                    "主轴输入 P_spindle（kW）": "3.9",
                    "10 kW 主轴负载（%）": "39"
                },
                {
                    "材料": "Alloy steel 4140",
                    "K_p（kW/(cm³/s)）": "3.29",
                    "刀具处 P_c（kW）": "4.72",
                    "主轴输入 P_spindle（kW）": "5.6",
                    "10 kW 主轴负载（%）": "55"
                },
                {
                    "材料": "Stainless 304",
                    "K_p（kW/(cm³/s)）": "2.94",
                    "刀具处 P_c（kW）": "4.21",
                    "主轴输入 P_spindle（kW）": "5.0",
                    "10 kW 主轴负载（%）": "50"
                },
                {
                    "材料": "Titanium Ti-6Al-4V",
                    "K_p（kW/(cm³/s)）": "1.77",
                    "刀具处 P_c（kW）": "2.54",
                    "主轴输入 P_spindle（kW）": "3.0",
                    "10 kW 主轴负载（%）": "30"
                },
                {
                    "材料": "Brass C36000",
                    "K_p（kW/(cm³/s)）": "1.90",
                    "刀具处 P_c（kW）": "2.72",
                    "主轴输入 P_spindle（kW）": "3.2",
                    "10 kW 主轴负载（%）": "32"
                }
            ]
        },
        {
            "caption": "钛合金粗加工受主轴功率限制吗？",
            "columns": [
                "项目",
                "数值",
                "怎么读"
            ],
            "rows": [
                {
                    "项目": "K_p (unit power)",
                    "数值": "1.65–1.77 kW per cm³/s",
                    "怎么读": "低于 4140——主轴不是瓶颈"
                },
                {
                    "项目": "10 kW turning ceiling",
                    "数值": "215–230 cm³/min",
                    "怎么读": "功率允许的去除率高于车间通常采用的水平"
                },
                {
                    "项目": "10 kW milling ceiling, cycle avg",
                    "数值": "170–185 cm³/min",
                    "怎么读": "按切削中占比 80% 折算的循环平均值"
                },
                {
                    "项目": "20 kW turning ceiling",
                    "数值": "430–460 cm³/min",
                    "怎么读": "翻倍的是上限，不是允许的切削量"
                },
                {
                    "项目": "Actual limiter",
                    "数值": "Heat and tool life",
                    "怎么读": "按 cutting-parameters 表的速度运行，并配高压冷却——冷却是前提，不是选项"
                }
            ]
        },
        {
            "caption": "20 kW 主轴能让去除率翻倍吗？",
            "columns": [
                "参数",
                "Ø12 刀具（算例）",
                "Ø20 刀具（示意）"
            ],
            "rows": [
                {
                    "参数": "Tool",
                    "Ø12 刀具（算例）": "Ø12 mm, 3-flute carbide end mill",
                    "Ø20 刀具（示意）": "Ø20 mm — an example, not a recommendation"
                },
                {
                    "参数": "Radial width a_e (mm)",
                    "Ø12 刀具（算例）": "6",
                    "Ø20 刀具（示意）": "10"
                },
                {
                    "参数": "Axial depth a_p (mm)",
                    "Ø12 刀具（算例）": "6",
                    "Ø20 刀具（示意）": "10"
                },
                {
                    "参数": "Feed speed V_f (mm/min)",
                    "Ø12 刀具（算例）": "2,388",
                    "Ø20 刀具（示意）": "2,000"
                },
                {
                    "参数": "MRR (cm³/min)",
                    "Ø12 刀具（算例）": "86",
                    "Ø20 刀具（示意）": "200"
                },
                {
                    "参数": "Cutting time for 25 cm³",
                    "Ø12 刀具（算例）": "17.5 s",
                    "Ø20 刀具（示意）": "7.5 s"
                }
            ]
        },
        {
            "caption": "同一台机床上，为什么铣削 MRR 低于车削？",
            "columns": [
                "步骤",
                "规则",
                "6061-T6，10 kW"
            ],
            "rows": [
                {
                    "步骤": "1",
                    "规则": "Turning ceiling: Q_max = 60 × 10 × 0.6375 / K_p, rounded to 5 cm³/min",
                    "6061-T6，10 kW": "425–505"
                },
                {
                    "步骤": "2",
                    "规则": "Milling column = 0.8 × the rounded turning column, rounded to 5 cm³/min",
                    "6061-T6，10 kW": "340–405"
                },
                {
                    "步骤": "3",
                    "规则": "20 kW columns = 2 × the 10 kW columns (exact doubling)",
                    "6061-T6，10 kW": "850–1,010 turning / 680–810 milling"
                }
            ]
        },
        {
            "caption": "粗加工时主轴负载应该控制在多少？",
            "columns": [
                "参数",
                "数值",
                "依据"
            ],
            "rows": [
                {
                    "参数": "Rated spindle power P_rated",
                    "数值": "10 / 20 kW",
                    "依据": "两种常见的立式加工中心功率档"
                },
                {
                    "参数": "Drive efficiency η",
                    "数值": "0.85",
                    "依据": "规划假设，不是实测值——请用机床厂数据确认"
                },
                {
                    "参数": "Roughing load factor L",
                    "数值": "0.75",
                    "依据": "70–85% 目标区间的中点（S5）"
                },
                {
                    "参数": "Usable cutting-power factor",
                    "数值": "0.85 × 0.75 = 0.6375 ≈ 0.64",
                    "依据": "每 kW 额定功率只有 0.64 kW 到达切屑"
                },
                {
                    "参数": "Tool condition",
                    "数值": "Sharp carbide",
                    "依据": "K_p 表是按锋利刀具编制的"
                },
                {
                    "参数": "Milling in-cut factor",
                    "数值": "0.80",
                    "依据": "S5 算例：循环中 80% 的时间在切削"
                },
                {
                    "参数": "Coolant and setup",
                    "数值": "Stable, no chatter",
                    "依据": "钢和不锈钢用大流量乳化液；钛用高压冷却；铝用大流量冷却或 MQL"
                }
            ]
        },
        {
            "caption": "铣削和车削的 MRR 公式是什么？",
            "columns": [
                "步骤",
                "量",
                "数值"
            ],
            "rows": [
                {
                    "步骤": "1",
                    "量": "Removal volume V",
                    "数值": "50 × 50 × 10 mm pocket = 25 cm³"
                },
                {
                    "步骤": "2",
                    "量": "Tool and engagement",
                    "数值": "Ø12 mm, 3-flute carbide end mill; V_c 300 m/min; f_z 0.10 mm/tooth; a_e = a_p = 6 mm"
                },
                {
                    "步骤": "3",
                    "量": "Spindle speed n = 1,000 × V_c / (π × D)",
                    "数值": "7,958 → take 7,960 rpm"
                },
                {
                    "步骤": "4",
                    "量": "Feed speed V_f = n × z × f_z",
                    "数值": "7,960 × 3 × 0.10 = 2,388 mm/min"
                },
                {
                    "步骤": "5",
                    "量": "MRR Q = a_e × a_p × V_f / 1,000",
                    "数值": "6 × 6 × 2,388 / 1,000 = 85.97 → 86 cm³/min"
                },
                {
                    "步骤": "6",
                    "量": "Cutting time T = V / Q",
                    "数值": "25 / 86 = 0.291 min = 17.5 s (21.8 s with 20% non-cutting)"
                },
                {
                    "步骤": "7",
                    "量": "Power check P_c = K_p × Q, spindle input P_c / 0.85",
                    "数值": "0.90 × 1.433 = 1.29 kW → 1.52 kW → 15.2% of 10 kW"
                },
                {
                    "步骤": "8",
                    "量": "Reading",
                    "数值": "Spindle only 15% loaded — the Ø12 cutter in a 50 mm pocket is tool-limited; the 425 cm³/min ceiling would need V_f 11,806 mm/min, five times beyond this cutter"
                }
            ]
        },
        {
            "caption": "如何把 MRR 换算成加工时间？",
            "columns": [
                "速率情形",
                "Q（cm³/min）",
                "25 cm³ 所需时间（s）"
            ],
            "rows": [
                {
                    "速率情形": "Worked example toolpath (Ø12 in 6061)",
                    "Q（cm³/min）": "86",
                    "25 cm³ 所需时间（s）": "17.5"
                },
                {
                    "速率情形": "Ø20 cutter example",
                    "Q（cm³/min）": "200",
                    "25 cm³ 所需时间（s）": "7.5"
                },
                {
                    "速率情形": "6061 10 kW turning ceiling",
                    "Q（cm³/min）": "425",
                    "25 cm³ 所需时间（s）": "3.5"
                },
                {
                    "速率情形": "304 planning low end",
                    "Q（cm³/min）": "130",
                    "25 cm³ 所需时间（s）": "11.5"
                },
                {
                    "速率情形": "4140 milling planning low end",
                    "Q（cm³/min）": "90",
                    "25 cm³ 所需时间（s）": "16.7"
                }
            ]
        },
        {
            "caption": "这些 MRR 数字用于报价时有多准？",
            "columns": [
                "冲突",
                "来源 A",
                "来源 B",
                "本页处理方式"
            ],
            "rows": [
                {
                    "冲突": "304 / 316 unit power",
                    "来源 A": "S3 handbook band 1.64–1.97 (150–200 HB, sharp tools)",
                    "来源 B": "S4 energy-study value 2.94 (austenitic 150–275 HB)",
                    "本页处理方式": "完整的 1.64–2.94 区间保留在表中；除非硬度和刀具都确认处于有利端，否则按 130 cm³/min 的低端报价"
                },
                {
                    "冲突": "C36000 unit power",
                    "来源 A": "S3 leaded brass 0.82",
                    "来源 B": "S4 leaded brass 1.90",
                    "本页处理方式": "0.82 与黄铜的物理量级一致（K_p ≈ k_c / 1,000，k_c ≈ 800 N/mm²），因此优先采用 0.82 端；200–465 区间作为登记包络保留"
                },
                {
                    "冲突": "1045 / 4140 ranges",
                    "来源 A": "S3 by 20 HB steps",
                    "来源 B": "S4 220–420 HB envelope",
                    "本页处理方式": "不是冲突——区间随硬度变化；不要描述成来源互相矛盾"
                }
            ]
        }
    ]
}