Milling of Superhard Materials at an Ensured Rational State of the Technological Cutting System. Part 1

Abstract—The demand for parts made from high-hardness materials (HRC 65) is steadily increasing. These materials are produced using special powder wire deposition technology. The machining of these parts encounters significant challenges. Grinding is not an option for several technical reasons, and metal cutting with end mills and face mills is required. Currently, there are no systematic guidelines available for this machining process, and there are no recommendations for maintaining optimal cutting system conditions. This work investigates face milling characteristics for such coatings using mechanically clamped carbide inserts. The aim of this work is to maintain optimal performance of the machine–fixture–tool–workpiece cutting system during milling of high-hardness parts to enhance the operational efficiency of the metal-cutting tool. Research objective. (1) To enhance the cutting tool performance. (2) To develop the criteria for assessing and controlling the current condition of the cutting system. (3) To predict the cutting system condition and maintain its optimal performance. Research techniques. Experimental analysis, computational modeling, and acoustic emission monitoring are used. Novelty. The scientific novelty of this work is (1) in establishing criteria for real-time assessment of the cutting system current state, and (2) a predictive methodology that enables both forecasting the cutting system state and controlling its operational parameters. Results. The feasibility of highly efficient milling of high-hardness materials while meeting the three critical requirements of machining productivity, surface finish quality and carbide insert life is shown. Conclusions. The criteria developed for the estimation of the cutting system state provide real-time process control while maintaining the required workpiece surface quality, machining productivity, and tool life.