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It is recommended to use high-speed milling to maintain an effective material removal rate and the required cutting-edge geometry. However, on the other hand, high speed increases wear, so the surface of the cutters is modified by deposition functional coatings. The wear of end mills made of CTS12D and H10F tungsten carbides during the high-speed processing of aluminum A97075 (B95T1) was compared. To increase the durability of the tools, well-proven technologies for deposition diamond-like and polycrystalline diamond coatings in microwave plasma with different film structures, which were determined by the coating growth conditions, were used. The milling cutter corner was mostly worn out, but the nature of the wear had its characteristics. It was revealed that at a forced cutting mode of about 1000 m/min, cutters made of CTS12D alloy with a nanocrystalline diamond coating with a "cauliflower" structure and with a diamond-like film showed 10% higher resistance. The primary wear mechanism was adhesive. Images of worn cutting edges were obtained using a 3D optical digital image processing system. [ABSTRACT FROM AUTHOR]

Active development of digital cyber-physical systems for application the mechanical processing and design of new technologies opens up new opportunities for increasing the efficiency of control and monitoring. Cutting tool as general element of the technological system includes preparatory stages of its development consisting of different subsystems: subsystem for developing design methods; subsystem of CAD/CAM cutting tools (CT), subsystem for developing tool machining schemes; subsystem of automated production of CT, grinding multi-coordinate machine with CNC; subsystem of monitoring and control. Combine a digital twin with 3D computer vision, indicators of the tool machining process and the integration of the main parameters and indicators determined by combining data, knowledge about the grinding process, where the synergetic mechanism of communication of virtual and physical processes is revealed. Focusing on planning the process of disign conical end mills, a prototype tool is created to study potential scenarios for the application of the proposed cyber-physical in the intelligent prediction of the processing process at the stage of virtual shaping, which can provide an idea of the industrial implementation of the digital twin at enterprises in the machine tool industry.

Drills with various flank surface shapes are widely used to machine holes. Drill teeth have flank surfaces of various shapes, flat, conical and helical. In this work, we have investigated the influence of radius of the generatriх in the form of a circular arc on the geometric parameters of the cutting wedge. It has been found that the range of changes in the clearance and rake angles along the cutting edge decreases with the decreasing radius of generatrix forming rake. It was found that a tool with a minimum permissible radius of curvature has the best distribution of rake and clearance angles of the blade along the cutting edge . The improvement reaches up to 40% compared conical flank surface. It was also found that in the case, when the generatrix radius decreases, the cutting edge increases by 18% compared to conical flank surface, which reduces the stress along the entire cutting wedge.

Micromachining is an up-to-date technology widely used in different advanced areas like electronics, aerospace and medical industries. For manufacturing components with highest precision and lowest surface roughness, small-sized end mills with working diameter of less than 1 mm are often used. In this paper, in order to determine the functional relationships between structural strength, cutting properties and geometry of small-sized cutting tools, the mathematical models of working part of micro milling cutters were derived.

Processing of high-precision holes in one technological operation is an urgent problem of advanced manufacturing. Processing of precise holes in parts for aerospace and machine-building industries with a diameter of up to 30 mm is performed during countersinking, deployment or grinding operations. These operations are applied only if there already exists a pre-treated hole. Monolithic three-fluted drills have been becoming common for processing high-precision holes of 7-8 quality over the last few years. The processing of various types of materials such as stainless steels, cast iron and heat-resistant steels requires rational geometric and structural parameters of the cutting tool. The nature of the load distribution between all the teeth during drilling plays a huge role in the processing efficiency. Even load distribution between the three teeth and a positive geometry improves self-centering and reduces the deviation from the specified axis of the hole. The drill sharpening provides positive geometry along the entire main cutting edge. The influence of the geometric parameters of the cutting edge of the screw groove on the shape of the drill bit is equally important. Existing approaches to the design of the thinning do not account for the influence of the geometric parameters of the cutting edge on the section of the screw groove. Analytical approaches to modelling of the main cutting edges are typically married with difficulties associated with achieving a smooth change in the angle of inclination to the tangent of the cutting edge. The complexity of the aforementioned task is largely due to the presence of critical points at the interface of the spiral groove and thinning. Determining the rational shape of two sections of the main cutting edge performed in this study is a complicated task that includes several steps needed to find the number of nodal points. Achieving a positive rake angle in the normal section to the cutting edge at the gash area that was formed via a special sharpening is one of the most important results of this paper. The rational shape of the cutting edge and the front surface provides an increase in the strength of the cutting part by 1.3 times.