The calculation for feed rate is a core concept in machining. Here's the formula and process:

1. Determine Spindle Speed (RPM): This is the rotational speed of your saw blade, set by your machine.
2. Find the Chipload: This is the manufacturer's recommended thickness of material that each tooth should remove per revolution. It varies by material. This calculator provides good starting points.
3. Count the Teeth: Identify the number of cutting teeth on your saw blade.
4. Apply the Formula: The feed rate is the product of these three values.
   Feed Rate (IPM) = RPM × Chipload (per tooth) × Number of Teeth

This gives you the linear speed, in inches per minute (IPM), at which you should move the material through the saw (or the saw through the material).

• Feed Rate (IPM): Inches Per Minute. The linear speed at which the workpiece is fed into the cutting tool.
• Spindle Speed (RPM): Revolutions Per Minute. The rotational speed of the cutting tool.
• Chipload: The thickness of the chip removed by a single cutting edge (tooth) in one revolution. This is the most critical variable for tool life and cut quality.
• PCD (Polycrystalline Diamond): An industrial-grade synthetic diamond used for the cutting tips on these blades due to its extreme hardness and abrasion resistance.
• Heat Buildup: The primary enemy of tool life. Caused by friction when chipload is too low, leading to premature tool wear.

"Listen to the cut. You can hear when a feed rate is wrong. If the blade is screaming or whining, you're likely running it too slow, causing it to rub and generate heat. A proper cut should sound like a steady, clean shearing or 'frying bacon' sound. Your ears are a great diagnostic tool." - CNC Production Manager

"The chipload values provided by tooling manufacturers are starting points. You may need to adjust them based on the rigidity of your machine, the quality of your work holding, and the depth of cut. Start with the recommended value, and then adjust your feed rate up or down by 5-10% to see if cut quality improves."

Example 1: Cutting MDF Sheets
You have a 6-tooth PCD blade running at 18,000 RPM. The recommended chipload for MDF is 0.015".
Feed Rate: `18,000 RPM * 0.015" * 6 teeth = 1,620 IPM`. This is a very high feed rate, typical for industrial beam saws or CNC routers designed for panel processing.

Example 2: Grooving Laminated Particleboard
You are using a 4-tooth blade at 16,000 RPM. Chipload for laminated board is around 0.013".
Feed Rate: `16,000 RPM * 0.013" * 4 teeth = 832 IPM`.

• Running Too Slow: This is the most common and most damaging mistake with diamond tooling. It doesn't save the tool; it destroys it through heat. The tool rubs instead of cutting, causing the diamond tips to dull or detach.
• Using the Wrong Chipload: Using a chipload meant for softwood on an abrasive material like carbon fiber will result in rapid tool wear. Always start with the manufacturer's recommendation for the specific material you are cutting.
• Ignoring Machine Rigidity: A very high feed rate can cause vibration and chatter on a less rigid machine, leading to poor cut quality even if the calculation is theoretically correct.
• Forgetting Depth of Cut: Deeper cuts may require a slightly lower feed rate or RPM to compensate for the increased load on the tool.

• CNC Routers: Setting the feed rate for nesting operations on MDF, particleboard, and other sheet goods.
• Beam Saws & Panel Saws: Programming industrial saws for high-speed cutting of laminated panels.
• Composite Machining: Cutting abrasive materials like carbon fiber, fiberglass, and Trespa panels where carbide tools wear out too quickly.