Angled Wheel Calculator

INPUT ACTUAL WHEEL WIDTH (F) 3.839 inch/mm

INPUT WHEEL ANGLE 30.000 degrees
INPUT CORNER RADIUS (A) 0.010 inch/mm
INPUT SHOULDER HEIGHT (B) 0.750 inch/mm
0.770
WHEEL WIDTH WITH NO SHOULDER 4.43290
USABLE WHEEL WIDTH (C) 3.988 inch/mm

Dressing Speed Calculators ID Bo

Optimum Dressing Amounts (ad) = 0.002mm to 0.003mm (0.00008" to 0.00012") Wheel Width
Overlap Ratio Chart (Ud) Calculate Diamond Width Bore Length
Desired Finish Ratio (Ud) Diamond Radius(rp) 0.01968 E: v Infeed Rate/Min
Rough 2 to 3 Dressing Amount(ad) 0.00010 F: vv Infeed Rate/Min
Normal 3 to 4 Effective Width(bd) 0.00396 G: vvv Infeed Rate/Min
Fine 6 to 8 Oscillation Speed

*For cluster diamonds use 35% of the measured width.

RPM of Grinding Wheel 71000 rpm (ns)
Diamond Width * 0.00396 inch/mm (bd)
Dressing Speed 35.00 inch or mm/min (Vd)
Overlap Ratio Calculated 8.0 ratio (Ud)
Calculated 8.0 ratio (Ud)
Distance/Revolution Calculated 0.00049 inch or mm/rev

Desired Overlap Ratio Input 8.0 ratio (Ud)

Required Dressing Speed 35.17 inch or mm/min (Vd)
Dressing Speed Calculator Distance per Revolution Legend Kilowatts to Horsepowe
Wheel RPM 1743 Input(s) Kilowatts
Distance traveled (inch or mm) / REV 0.0030 Output(s) Horsepowe
Dressing Speed (inch or mm) / MIN 5.229 Information
Horsepower to Kilowat
Horsepowe
RPM Surface Speed Calculator Kilowatts
Metric
Wheel Diameter (mm) 48.00
M/s 50 SFMP 9850
RPM 19894
 English
Wheel Diameter (in) 0.17 4.25323
sfpm 20 M/s 0.1
RPM 456

Rotary Disk Dresser

Metric
Diamond Diam. (mm) 3.25
M/s 10.0 SFMP 1970
RPM 58765
English
Diamond Diam. (inch) 4.700 119.38
sfpm 3000 M/s 15.2
RPM 2436
Radius Squ 0.01968
Radius Squ0.000387
Dress Dept 0.0008
0.005554
0.011108
 Corner Radius Profiling Allowance Calculator
Input Corner Radius on Wheel
Insert Profile Allowance for X
Insert Profile Allowance for Z
#VALUE!

ID Bore Grind Using Straight Plunge With Oscillation

Wheel Width 0.23600 0.118 Distance Traveled
Bore Length 0.05500 0.17300 Time wheel travels
E: v Infeed Rate/Min 0.01140 0.00019 v Infeed Amount 0.000027
F: vv Infeed Rate/Min 0.00750 0.00013 vv Infeed Amount 0.000018
G: vvv Infeed Rate/Min 0.00200 0.00003 vvv Infeed Amount 0.000005
Oscillation Speed 40.0 Optimun Feed Rates for roughing .00002-4"

Taper Corrections Fine Adjustment INCH / METRIC CALCULATOR

Part Length 6.300000 Inch Metric
Measurement Length 1.010000 0.00002 0.0005
Taper Amount of Measurement Length 0.000050 Metric Inch
Fine Adjustment Amount 0.000312 6.00000 0.23622

Time Based Dress for G202 Cycle*

Stock to be Removed Before Dress 0.05000
Kilowatts to Horsepower Current Grinding Feed Rate 0.10000
12.00 Kw Set G202 Parameter D,E, or F to 30.0
16.08 Hp *This will calculate the time needed to remove X amount of stock from the
workpiece prior to dress. This time based dress is used when dressing in the
grind cycle (G202).
Horsepower to Kilowatts
16.00 Hp
11.94 Kw

Disk Dresser Ratio Calculator Workpiece R

Metric English
Wheel Peripheral 50.00 20 Input Diame
 Desired Ratio 0.80 0.20 Input Work Peripheral Spe
Diamond Peripheral 40.00 4.00 Revolutions per Min
Diamond Diameter 120.00 4.70 Revolutions per
Calculated rpm 6366 3 Dwell time (Q val
0 Total revolutio
Desired Revolutio
Set Q Value

Infeed Per Revolution

Current RPM 456
Current Infeed Rate 0.015
Amount per Revolution 0.0000329
Desired Amount per Rev. 0.0000250
Set RPM to 600
OR Set Infeed Rate to 0.0114
owance Calculator 0.7071068 0.9999984769
0.1000 mm or inch 0.1414214 0.1000001523
0.0293 mm or inch 45
0.0293 mm or inch 0.0414214

Wheel Grit Information

0.09433 US Mesh Avg. Grain Ideal D6 0.77
0.14150 GRIT SIZE Size In Dress Depth Ra Range
Per Stroke 8 0.09290 0.00372 63 D7 4.432895
Per Stroke 10 0.07870 0.00315 63
Per Stroke 12 0.06660 0.00266 63
14 0.05510 0.00220 32-63
16 0.04640 0.00186 32-63
20 0.03340 0.00134 32-63
24 0.02790 0.00112 32-63
30 0.02360 0.00094 32-63
36 0.01960 0.00078 32-63
46 0.01390 0.00056 32-63
54 0.01180 0.00047 32-63
60 0.00980 0.00039 32-63

Cycle* 70 0.00830 0.00033 32-63

in or mm 80 0.00700 0.00028 32-63
in or mm 90 0.00590 0.00024 20-32
seconds 100 0.00490 0.00020 12-16
mount of stock from the 120 0.00410 0.00016 10 or Less
used when dressing in the 150 0.00290 0.00012 8 or Less
180 0.00240 0.00010 7 or Less
220 0.00208 0.00008 6 or Less

Workpiece RPM/Dwell Time (Q) Calculator

Diameter 1 Diameter 2 Diameter 3 Diameter 4
Input Diameter 2.0 11.4 1.6 1.7
Input Work Peripheral Speed 40.0 140.0 70.0 70.0
Revolutions per Minute 76.3 47.0 167.0 157.2
Revolutions per sec 1.3 0.8 2.8 2.6
Dwell time (Q value) 0.8 6.5 8.0 9.0
Total revolutions 1.0 5.1 22.3 23.6
Desired Revolutions 4.0 6.0 15.0 15.0
Set Q Value To 3.1 7.7 5.4 5.7
50.8 0.2030457
288.798 0.7106599
40.64 0.3553299
43.18 0.3553299
D5+(D4*2)

D2/COS(RADIANS(D3))
Copyright 20012 [Dale Savington]. All Rights Reserved.

Angle Head Wheel Calculator for Calculating Wheel Width

Entries can be either (mm or Inch)
FORMULAS

Total Wheel Width 0.000 Pythagorea

Wheel Angle (Normally 30 Deg.) ###

Corner radius between long and short leg ###

Short Leg Length ###

Long Leg Length ###

###

Usable Long Length (calculating corner radius) 0.000 tan B=b/a

###

Fill in all the information in the Charcoal Colored cells.- Corner radius can be ###
left without an entry but all the rest of the cells need to be filled
A= A angle
a= opposite
GRINDING CALCULATOR
INCH INCH PLUNGE MULTI TRAVERSE Q'w CALC Q'w CALC
UNITS GRIND PLUNGE GRIND PLUNGE TRAVERSE

WORKPIECE DIAMETER X INCH 0.805 2 0.499 2 1

STOCK ALLOWANCE A INCH 0.015 0.02 0.01 0.02 0.02
SWITCHOVER v/vv B INCH 0.0015 0.001 0.001 0.001 0.001
SWITCHOVER vv/vvv C INCH 0.0005 0.0005 0.001 0.0005 0.0005
METAL REMOVAL RATE 0.15 1.2 0.5 1.69 0.74
INFEED SPEED V D IPM 0.0178 N/A 0.025 N/A
INFEED SPEED VV E IPM #VALUE! N/A N/A 0.01 N/A
INFEED SPEED VVV F IPM #VALUE! N/A N/A 0.005 N/A
INFEED AMOUNT V D INCH N/A N/A 0.00030 N/A 0.0005
INFEED AMOUNT VV E INCH N/A 0.00071 0.00020 N/A 0.00025
INFEED AMOUNT VVV F INCH N/A 0.00036 0.00020 N/A 0.0001
TYPE OF INFEED H 0 or 1 N/A 1 0 N/A 0

SPARK OUT PLUNGE Q SEC 5 N/A N/A 5 N/A

SPARK OUT MULTI-PLUNGE Q SEC N/A 0.5 N/A N/A N/A
SPARK OUT STROKES I STROKE N/A 4 6 N/A 6
TRAVERSE SPEED J IPM N/A 25 57 N/A 55

WORKPIECE WIDTH INCH 8 1 6

WHEEL WIDTH INCH 1 2 0.5 1.25 1.25
OVERLAP FACTOR N/A 10 4 N/A 6

DRESSING TIME PER PART SEC 90 90 0

OVERTRAVEL POSITION 1 K INCH N/A 0.02 0 N/A
OVERTRAVEL POSITION 2 M INCH N/A 0.5 0.25 N/A
WORKPIECE PERIPHERAL FPM 60 65 60 65 68.85
WORKPIECE RPM RPM 285 124 459 124 263
PLUNGES IN G9205 N/A 5 N/A

CYCLE TIME SECONDS #VALUE! 331 144 32.3 334

CYCLE TIME MINUTES #VALUE! 5.52 2.40 0.54 5.56

Rough Grind Time v #VALUE! 160.5 39 22.8 249

Medium Grind Time vv #VALUE! 29 0 1.5 13
Finish Grind Time vvv #VALUE! 58 7 3.0 33
Spark Out Time Q 5 3 N/A 5 N/A
Spark Out Time Strokes I N/A 82 8 N/A 39

THIS CALCULATION SHEET WAS DEVELOPED BY TENNESSEE GRINDING SPECIALISTS, INC.

FOR THE EXCLUSIVE USE OF OUR CUSTOMERS. IT IS MEANT TO PROVIDE AN ACCURATE
ESTIMATE OF CYCLE TIME, WHEN THE DETAILED PARAMETERS ARE USED.
ALL GRINDING CYCLES ARE SUBJECT TO VARIOUS FACTORS AND RESULTS ARE NOT
GUARANTEED. NO WARRANTY, WRITTEN OR IMPLIED IS CONVEYED WITH THIS CALCULATOR.

TO USE: SELECT TYPE OF GRINDING FROM SELECTED COLUMNS. ENTER WORK DIAMETER,
STOCK ALLOW., SWITCHOVERS ETC. SELECT APPROPRIATE Q'W (0-2 FOR MOST 10 HP MACH)
CALCULATOR WILL PROVIDE ROUGH, MEDIUM AND FINE FEEDS, ALONG WITH CYCLE TIME.
PROTECTED CELLS CONTAIN FORMULAS AND SHOULD NOT BE CHANGED!!
YOU CAN ENTER A DESIRED ROUGHING SPEED/AMOUNT IN THE Q'W COLUMNS, AND CALC
WILL SOLVE FOR Q'W.
GRINDING CALCULATOR
METRIC METRIC PLUNGE MULTI TRAVERSE Q'w CALC Q'W CALC
UNITS GRIND PLUNGE GRIND PLUNGE TRAVERSE

WORKPIECE DIAMETER X MM 7 50.8 50.8 50.8 50.8

STOCK ALLOWANCE A MM 0.085 0.5 0.5 0.5 0.3
SWITCHOVER v/vv B MM 0.0135 0.025 0.025 0.025 0.02
SWITCHOVER vv/vvv C MM 0.0025 0.012 0.012 0.012 0.01
METAL REMOVAL RATE 0.165 1.4 1 1.86 0.99
INFEED SPEED V D MM/MIN 0.450 0.527 N/A 0.7 N/A
INFEED SPEED VV E MM/MIN 0.100 N/A N/A 0.271 N/A
INFEED SPEED VVV F MM/MIN 0.020 N/A N/A 0.135 N/A
INFEED AMOUNT V D MM N/A N/A 0.0114 N/A 0.017
INFEED AMOUNT VV E MM N/A 0.0064 0.0046 N/A 0.008
INFEED AMOUNT VVV F MM N/A 0.0032 0.0023 N/A 0.004
TYPE OF INFEED H 0 or 1 N/A 0 1 N/A 1

SPARK OUT PLUNGE Q SEC 2 N/A N/A 5 N/A

SPARK OUT MULTI-PLUNGE Q SEC N/A 0.5 N/A N/A N/A
SPARK OUT STROKES I STROKE N/A 4 10 N/A 8
TRAVERSE SPEED J MM/MIN N/A 1676 838 N/A 704

WORKPIECE WIDTH MM 200 50.8 75

WHEEL WIDTH MM 50.8 25.4 32
OVERLAP FACTOR N/A 4 4 N/A 6

DRESSING TIME PER PART SEC 15

OVERTRAVEL POSITION 1 K MM N/A 0.5 0.5 N/A 0
OVERTRAVEL POSITION 2 M MM N/A 12.7 12.7 N/A 20
WORKPIECE PERIPHERAL M/S 0.35 0.35 0.35 0.35
WORKPIECE RPM RPM 955 132 132 0 132
PLUNGES IN G9205 N/A 5 N/A

CYCLE TIME SECONDS 13.8 213 502 29.5 407

CYCLE TIME MINUTES 5:31 3.54 8.37 11:47 6.79

Rough Grind Time v 4.8 135.3 382 20.4 267

Medium Grind Time vv 3.3 16 26 1.4 20
Finish Grind Time vvv 3.8 29 48 2.7 40
Spark Out Time Q 2 3 N/A 5 N/A
Spark Out Time Strokes I N/A 31 46 N/A 65

Tennessee Grinding Specialists specializes in training on CNC cylindrical grinders, with a heavy emphasis on
machines by Studer. We can provide basic to advanced training on all Studer machines, as well as Applications
support, process development, and assistance in machine specification.

We are located in Jonesborough, Tennessee. Visit our website at: www.tennesseegrinding.com

Call us for a quotation on your next training project. 423-791-0694. Ask for Bob Beals
s Applications
Hardness Conversion Table
Approximate Hardness Equivalents Covering Range of Rockwell C and Rockwell B Sca
-
VPN ROCKWELL SCALES BRINELL SCOPE
DPH BHN BHN
HV/10 A B C D E F G H K 15N 30N 45N 15T 30T 45T 500kg 3000kg
1865 92 80 87 97 92 87
1787 92 79 86 96 92 87
1710 91 78 85 96 91 86
1633 91 77 84 96 91 85
1556 90 76 83 96 90 84
1478 90 75 83 95 89 83
1400 89 74 82 95 89 82
1323 89 73 81 95 88 81
1245 88 72 80 95 87 80
1160 87 71 80 94 87 79
1076 87 70 79 94 86 78 101
1004 86 69 78 94 85 77 99
940 86 68 77 93 84 75 97
900 85 67 76 93 84 74 95
865 85 66 75 93 83 73 92
832 84 65 75 92 82 72 739 91
800 84 64 74 92 81 71 722 88
772 83 63 73 91 80 70 705 87
746 83 62 72 91 79 69 688 85
720 82 61 72 91 79 68 670 83
697 81 60 71 90 78 67 654 81
674 81 59 70 90 77 66 634 80
653 80 58 69 89 76 64 615 78
633 80 57 69 89 75 63 595 76
613 79 56 68 88 74 62 577 75
595 79 120 55 67 88 73 61 560 74
577 78 120 54 66 87 72 60 543 72
560 78 119 53 65 87 71 59 523 71
544 77 119 52 65 86 70 57 512 69
528 77 118 51 64 86 69 56 496 68
513 76 117 50 63 86 69 55 481 67
498 75 117 49 62 85 68 54 469 66
484 75 116 48 61 85 67 53 455 64
471 74 116 47 61 84 66 51 443 63
458 74 115 46 60 84 65 50 432 62
446 73 115 45 59 83 64 49 421 60
434 73 114 44 59 83 63 48 409 58
423 72 113 43 58 82 62 47 400 57
412 72 113 42 57 82 61 46 390 56
402 71 112 41 56 81 60 44 381 55
392 71 112 40 55 80 60 43 371 54
382 70 111 39 55 80 59 42 362 52
372 70 110 38 54 79 58 41 353 51
363 69 110 37 53 79 57 40 344 50
354 69 109 36 52 78 56 38 336 49
345 68 109 35 52 78 55 37 327 48
336 68 108 34 51 77 54 36 319 47
327 67 108 33 50 77 53 35 311 46
318 67 107 32 49 76 52 34 301 44
310 66 106 31 48 91 76 51 33 294 43
302 66 105 30 48 91 75 50 31 286 42
294 65 104 29 47 89 75 50 30 279 41
286 65 104 28 46 88 74 49 29 271 41
279 64 103 27 45 87 73 48 28 264 40
272 64 103 26 45 86 73 47 27 258 39
266 63 102 25 44 85 72 46 26 253 38
260 63 101 24 43 84 72 45 24 247 37
254 62 100 23 42 83 71 44 23 93 82 72 201 240 36
248 62 99 22 42 81 71 43 22 93 82 71 195 234 35
243 61 98 21 41 79 70 42 21 93 81 70 189 228 35
238 61 97 20 40 78 69 42 20 92 81 69 184 222 34
234 60 97 19 77 92 80 69 181 218 34
230 59 96 18 76 92 80 68 179 214 33
226 59 96 17 75 92 80 68 177 210 33
222 58 95 16 74 92 79 67 175 208 32
217 58 95 15 73 92 79 67 171 205 31
213 58 94 14 73 91 79 66 169 203 31
208 57 93 13 71 91 78 66 167 200 30
204 57 92 12 70 100 91 78 65 163 195 30
200 56 92 11 69 100 91 77 64 162 193 29
196 56 91 10 68 100 90 77 64 160 190 28
192 56 90 9 66 99 90 76 63 157 185 27
188 55 89 8 64 98 90 76 62 154 180 26
184 54 88 7 63 97 90 75 61 151 176 26
180 54 87 6 61 97 89 75 60 148 172 26
176 53 86 5 59 96 89 74 59 145 169 25
172 53 85 4 58 95 89 74 58 142 165 25
168 52 84 3 56 94 88 73 57 140 162 25
164 51 83 2 54 93 88 72 56 137 159 24
160 51 82 1 53 92 88 72 55 135 156 24
156 50 81 0 51 91 87 71 54 133 153 24
152 50 80 49 91 87 70 53 130 150
148 49 79 48 90 87 70 52 128 147
144 49 78 46 89 86 69 51 126 144
141 48 77 44 88 86 68 50 124 141
139 47 76 43 87 86 68 49 122 139
137 47 75 100 41 86 85 67 49 120 137
135 46 74 99 39 85 85 66 48 118 135
132 46 73 99 38 85 85 66 47 116 132
130 45 72 98 36 84 84 65 46 114 130
127 45 71 100 98 35 83 84 64 45 112 127
125 44 70 100 97 33 82 84 64 44 110 125
123 44 69 99 96 31 81 83 63 43 109 123
120 43 68 98 96 30 80 83 62 42 107 121
118 43 67 98 95 28 79 83 62 41 106 119
116 42 66 97 95 27 78 82 61 40 104 117
115 42 65 96 94 25 78 82 60 39 102 116
114 42 64 96 94 24 77 82 60 38 101 114
113 41 63 95 93 22 76 81 59 37 99 112
112 41 62 95 92 21 75 81 58 36 98 110
111 40 61 94 92 19 74 81 57 35 96 108
110 40 60 93 91 18 73 81 57 34 95 107
108 39 59 93 91 16 72 80 56 32 94 106
107 39 58 92 90 15 71 80 55 31 92 104
106 38 57 91 90 13 71 80 55 30 91 102
105 38 56 91 89 12 70 79 54 29 90 101
104 38 55 90 88 10 69 79 53 28 89 99
103 37 54 90 88 9 68 79 53 27 87
102 37 53 89 87 7 67 78 52 26 86
101 36 52 88 87 6 66 78 51 25 85
100 36 51 88 86 4 65 78 51 24 84
100 35 50 87 86 3 65 77 50 23 83
99 35 49 87 85 64 77 49 22 82
98 35 48 86 85 63 77 49 21 81
97 34 47 85 84 62 76 48 20 80
96 34 46 85 83 61 76 47 19 79
95 33 45 84 83 60 76 46 18 79
95 33 44 84 82 59 75 46 17 78
94 32 43 83 82 58 75 45 16 77
93 32 42 82 81 58 75 44 15 76
92 31 41 82 81 57 74 44 14 75
91 31 40 81 80 56 74 43 13 74
90 31 39 80 79 55 74 42 11 74
90 30 38 80 79 54 73 42 10 73
89 30 37 79 78 53 73 41 9 72
88 29 36 79 78 100 52 73 40 8 71
88 29 35 78 77 100 52 72 40 7 71
87 28 34 77 77 99 51 72 39 6 70
87 28 33 77 76 99 50 72 38 5 69
86 28 32 76 75 99 49 71 38 4 68
86 27 31 76 75 98 48 71 37 3 68
85 27 30 75 74 98 47 71 36 2 67
85 26 29 74 74 98 46 70 36 1 66
84 26 28 74 73 97 45 70 35 66
84 25 27 73 73 97 45 70 34 65
83 25 26 73 72 97 44 69 33 65
83 24 25 72 71 96 42 69 33 64
82 24 24 71 71 96 42 69 32 64
82 24 23 71 70 96 41 68 31 63
81 23 22 70 70 95 40 68 31 63
81 23 21 70 69 95 39 68 30 62
 80 22 20 69 69 95 38 68 29 62
80 22 19 68 68 94 38 67 29 61
79 21 18 68 67 94 37 67 28 61
79 21 17 67 67 93 36 67 27 60
78 21 16 67 66 93 35 66 26 60
78 20 15 66 66 93 34 66 26 59
77 14 65 65 92 33 66 25 59
77 13 65 65 92 32 65 24 58
76 12 64 64 92 32 65 24 58
76 11 64 64 91 31 65 23 57
75 10 63 63 91 30 64 22 57
75 9 62 62 91 29 64 22 56
74 8 62 62 90 28 64 21 56
74 7 61 61 90 27 63 20 56
73 6 61 61 90 26 63 20 55
73 5 60 60 89 26 63 19 55
72 4 59 60 89 25 62 18 55
72 3 59 59 88 24 62 17 54
71 2 58 58 88 23 62 17 54
71 1 58 58 88 22 61 16 53
70 0 57 57 87 21 61 15 53
DPH BHN BHN
HV/10 A B C D E F G H K 15N 30N 45N 15T 30T 45T 500kg 3000kg
-
VPN ROCKWELL SCALES BRINELL SCOPE
and Rockwell B Scales

U.T.S.

Kpsi Mpa

320 2206
310 2137
300 2069
290 2000
282 1944
274 1889
266 1834
257 1772
245 1689
239 1648
233 1607
227 1565
221 1524
217 1496
212 1462
206 1420
200 1379
196 1351
191 1317
187 1289
182 1255
177 1220
173 1193
169 1165
165 1138
160 1103
156 1076
152 1048
147 1014
144 993
140 965
137 945
133 917
129 889
126 869
124 855
121 834
118 814
115 793
112 772
109 752
107 738
106 731
104 717
102 703
100 690
99 683
98 676
96 662
95 655
93 641
91 627
88 607
86 593
84 579
83 572
81 558
79 545
78 538
76 524
75 517
73 503
Kpsi Mpa

U.T.S.
 Qw' Calculator Recommended Metal Removal Rates

Workpiece Diameter Coarse Medium Fine

Qw' = Metal Removal Rate Input Known Values in mm Less than 20mm (0.800") 1 to 4 0.33 to 1.33 0.08 to 0.33
ae = Infeed per workpiece revolution 0.0002 0.00508 Greater than 20mm (0.800") 0.6 to 2 0.2 to 0.67 0.05 to 0.17
dw = Workpiece diameter 0.208 5.2832
nw = Workpiece RPM 350 8890 Material Vs
Vf = Feed rate 0.016 0.4064 Steel, hardened 35/45
Vw = Workpiece sfpm 0.5 12.7 Steel, unhardened 35/45

Qw' = 0.1124214994 Plunge

Qw' = 0.4918440597 Traverse
 What is Process Capabi

A process capability index uses both the

process variability and the process
specifications to determine whether the process
is "capable"

Definitions of various process capability indices

Sample estimates of capability indices

Plot showing Cp for varying process widths

Translating capability into "rejects"

One-sided specifications and the corresponding

capability indices
 What is Process Capability?

Process capability compares the output of an in-control process to the specification limits by
using capability indices. The comparison is made by forming the ratio of the spread between
the process specifications (the specification "width") to the spread of the process values, as
measured by 6 process standard deviation units (the process "width").

Process Capability Indices

We are often required to compare the output of a stable process with the process
specifications and make a statement about how well the process meets specification. To do
this we compare the natural variability of a stable process with the process specification
limits.

A capable process is one where almost all the measurements fall inside the specification
limits. This can be represented pictorially by the plot below:

Diagram demonstrating a capable process

There are several statistics that can be used to measure the capability of a process: Cp,
Cpk, Cpm.

Most capability indices estimates are valid only if the sample size used is 'large enough'.
Large enough is generally thought to be about 50 independent data values.
The Cp, Cpk, and Cpm statistics assume that the population of data values is normally
distributed. Assuming a two-sided specification, if muand sigmaare the mean and standard
deviation, respectively, of the normal data and USL, LSL, and T are the upper and lower
specification limits and the target value, respectively, then the population capability indices
are defined as follows:
Cp = (USL - LSL)/6*sigma

Cpk = MIN[(USL-mu)/(3*sigma), (mu-LSL)/(3*sigma)]

Cpm = (USL-LSL)/{6*SQRT(s**2 + (mu-T)**2)}

Sample estimators for these indices are given below. (Estimators are indicated with a "hat"
over them).

Chat(p) = (USL - LSL)/6*s

Chat(pk) = MIN[(USL-m)/(3*s), (m-LSL)/(3*s)]

Chat(pm) = (USL-LSL)/{6*SQRT(s**2 + (m-T)**2)}

The estimator for Cpk can also be expressed as Cpk = Cp(1-k), where k is a scaled distance
between the midpoint of the specification range, m, and the process mean, mu.
Denote the midpoint of the specification range by m = (USL+LSL)/2. The distance between
the process mean, mu, and the optimum, which is m, is mu- m, where m <= mu <= LSL.
The scaled distance is

k = |m - mu|/{(USL - LSL)/2}, 0 <= k <= 1

(the absolute sign takes care of the case when mu). To determine the estimated value, khat,
we estimate muby xbar. Note that xbar <= USL.

The estimator for the Cp index, adjusted by the k factor, is

Chat(pk) = Chat(p)(1 - k)

Since
To get0an
<= k <=
idea 1, itvalue
of the follows
of that Chat(pk)
the Cp <=
statistic forChat(p).
varying process widths, consider the
following plot

4 plots showing the value of Cp for varying process widths

This can be expressed numerically by the table below:
USL - LSL
Cp
Rejects
% of spec used

where ppm = parts per million and ppb = parts per billion. Note that the reject figures are
based on the assumption that the distribution is centered at mu.
We have discussed the situation with two spec. limits, the USL and LSL. This is known as the
bilateral or two-sided case. There are many cases where only the lower or upper
specifications are used. Using one spec limit is called unilateral or one-sided. The
corresponding capability indices are
C(pu) = (allowable upper spread)/(actual upper spread) =
(USL - mu)/(3*sigma)
and
C(pu) = (allowable lower spread)/(actual lower spread) =
(mu - LSL)/(3*sigma)
where muand sigmaare the process mean and standard deviation, respectively.

Estimators of Cpu and Cpl are obtained by replacing muand sigmaby Xbarand s,
respectively. The following relationship holds

Cp = (Cpu + Cpl) /2.

This can be represented pictorially by

Graph demonstrating upper actual and allowable upper spread

Note that we also can write:

Cpk = min {Cpl, Cpu}.

Total Sigmas (Standard Deviations)
6sigma8sigma10sigma12sigma
1 1.33 1.66 2
0.27% 64 ppm .6 ppm 2 ppb
100 75 60 50

4.23
 Target 1.00000 0.167450 0.37523 0.20200
Total Tolerance 0.01000 0.000100 0.00015 0.00200
USL 1.00500 0.167500 0.37530 0.20300 0.00000
LSL 0.99500 0.167400 0.37515 0.20100 0.00000

Example
Part Number ID 0.16745 OD 0.37523 OD Face 0.202
1 1.0010 0.000050 210.000000 170.000000
2 1.0030 0.000050 275.000000 180.000000
3 1.0010 0.000050 300.000000 170.000000
4 1.0000 0.000050 290.000000 170.000000
5 1.0000 0.000045 260.000000 170.000000
6 1.0000 0.000050 270.000000 160.000000
7 1.0010 0.000040 280.000000 150.000000
8 0.9990 0.000040 300.000000 150.000000
9 0.9999 0.000030 280.000000 150.000000
10 0.9999 0.000035 300.000000 150.000000
11 1.0000 0.000025 300.000000 150.000000
12 1.0000 0.000025 300.000000 150.000000
13 1.0000 0.000020 310.000000 150.000000
14 1.0000 0.000020 320.000000 150.000000
15 1.0010 0.000020 300.000000 150.000000
16 1.0020 0.000030 320.000000 160.000000
17 1.0000 0.000015 330.000000 150.000000
18 0.9999 0.000005 310.000000 150.000000
19 1.0020 0.000005 320.000000 150.000000
20 1.0020 0.000000 320.000000 150.000000
21 1.0010 -0.000005 320.000000 150.000000
22 1.0000 -0.000010 310.000000 150.000000
23 1.0020 -0.000010 330.000000 150.000000
24 1.0020 -0.000010 310.000000 140.000000
25 1.0010 -0.000015 310.000000 150.000000
26 0.9999 -0.000015 310.000000 170.000000
27 1.0020 -0.000020 310.000000 140.000000
28 1.0020 -0.000025 310.000000 140.000000
29 1.0010 -0.000030 310.000000 140.000000
30 1.0020 -0.000035 310.000000 130.000000
31 1.0000 -0.000040 310.000000 130.000000
32 1.0020 -0.000045 310.000000 120.000000
33 1.0020 -0.000045 310.000000 130.000000
34 1.0010 -0.000055 300.000000 140.000000
35 1.0020 -0.000066 300.000000 150.000000
36 1.0000 -0.000060 300.000000 150.000000
37 1.0020 -0.000070 280.000000 110.000000
38 1.0020 -0.000080 290.000000 110.000000
39 1.0020 -0.000085 280.000000 130.000000
40 0.9999 -0.000090 290.000000 120.000000
41 1.0020 -0.000090 280.000000 140.000000
42 1.0020 -0.000095 280.000000 120.000000
43 1.0010 -0.000100 260.000000 130.000000
44 1.0000 -0.000120 250.000000 140.000000
45 1.0020 -0.000125 240.000000
46 1.0020 -0.000130 250.000000
47 1.0000 -0.000130 250.000000
 48 1.0020
49 1.0010
50 0.9999
51 1.0020
52 1.0020
53 1.0000
54 1.0020
55 1.0020
56 1.0010
57 1.0020
58 1.0000
59 1.0020
60 1.0020
61 1.0020
62 1.0000
63 1.0020
64 1.0010
65 0.9999

Example
Min 0.9990 0.167320 0.375210 0.201100 0.0000
Max 1.0030 0.167500 0.375330 0.201800 0.0000
Mean 1.0011 0.167429 0.375294 0.201457 #DIV/0!
STDEV 0.0010 0.000055 0.000025 0.000159 #DIV/0!
Pp (Cp without subgroups) 1.7187 0.301572 0.9810 2.0956 #DIV/0!
Ppk (Cpk without subgroups) 1.3522 0.173757 0.0821 0.9573 #DIV/0!
Difference 0.000180 0.000120 0.000700
# of Parts Ran 47.000000 47.000000 44.000000
Change per Part 0.000004 0.000003 0.000016
Trend Correction Amount 0.00001 0.00002 0.00010
Trend Part Value* 3 8 6

G9336 A= 3 X= 0.00001
 Insert Nominal Size
Insert Total Tolerance
0.00000 Calculated Upper Spec Limit ID 0.16745
0.00000 Calculated Lower Spec Limit 0.000060

Insert Name of Characteristic 0.000040

Insert as much data as possible (min 30 parts) 0.000020
Cpk works better with 50 +
0.000000
-0.000020
-0.000040
-0.000060
-0.000080
-0.000100
-0.000120
-0.000140

350.000000

300.000000

250.000000

200.000000

150.000000

100.000000

50.000000

0.000000

200.000000
180.000000
160.000000
140.000000
120.000000
100.000000
80.000000
60.000000
40.000000
20.000000
0.000000
 80.000000
60.000000
40.000000
20.000000
0.000000

Insert Name of Characteristic

0.0000 Calculated Values.

0.0000 Calculated Values.
#DIV/0! Calculated Values.

#DIV/0! Calculated Values.
#DIV/0! Calculated Values.

#DIV/0! Calculated Values.
ID 0.16745
Wheel 1 Width (939)
Dress Angle (940)
SD= Snap Depth (960)
Back Angle (961)
R=Radius (962)
C=1/2 cord (967)
SIN B (968)
1/2 Wheel Width (938)
Sine of Angle (964)
Move Rad to Left (970)
Length For Taper (939-976)
Sine of Dress Angle (975)
True Radius for Offset (976)
X=Swing Angle (969)
START Z POS. (972)
START X POS. (971)
Profiling allowance
Input
Output
Calculations
(Variable Number)
0.51300 inches (10060)
90.00000 Degrees Wheel 2 X Offset (12368)
0.01000 inches Wheel 4 X Offset (12384)
5.00000 Degrees Wheel 4 Z Offset (12385)
0.14600 inches Wheel 4 C Offset (12386)
0.05310 C=SQRT of SD(2*R-SD)=SinB=C/R
0.36372 Radians of X Swing Angle
0.25650 inches
0.08716 Factor amount to calculate Start X Position
0.11050 Offsets True radius to left side of wheel
0.36700 inches Used for Back Taper Calculation
1.00000 Factor amount to calculate Start Z Position
0.14600 Depends on Dress Angle
21.32906 Degree (ARC SIN OF 968)
-0.11050 Right Side of Wheel Z position inches
0.06397 Finish Depth Right Side X position inches
Profile Allowance needed when going from small
to Large Radii (roughly the difference)
 Z Start #VALUE!

SWING ANGLE(#940) 75.00000

SIN of SWING ANGLE 0.96593

RADIUS(#962) 0.14600
TRUE RADIUS FOR OFFSET 0.14103

0.31390

0.54720