The possibility of controlling the effectiveness of the cutting process taking into account the quality of replaceable inserts in high-precision machining of parts to prevent spindle imbalance and tool destruction with low quality of the inserts is considered. Keywords: cutting, replaceable insert, spindle, imbalance, machining accuracy. boris@knastu.ru

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The paper reports the concept, the methodology and results of the investigation of possibilities in the application of compound hard-alloy end millers equally with monolithic ones. It is shown that in the majority of operation conditions for general mechanical engineering the compound millers ensure the reduction of tool costs in the cost price of a product at the expense of tool hard alloy saving through manufacturing a miller shank with the use of cheaper material and a place of joining a shank and a cutting element ensures miller operation on high performance modes of cutting without detriment to productivity and machining quality. Material costs at the expense of the reduction of tool hard alloy used are decreased by 30-70% depending on material of a shank and a miller length. The example of compound miller design is presented. The method and results of the deformation computer simulation of such a miller under different operation conditions, error values in machining with a compound miller are illustrated.

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Physical, mechanical and operational properties of tool materials were evaluated by various methods and techniques. However, those that allowed predicting performance of the metal-cutting tools in various operating conditions were becoming more and more in demand. The paper provides certain results of the pendulum scribing (scratching) introduction in evaluating and predicting performance of the coated tool. The parameter under study was crack resistance (resistance to formation and growth of cracks) of the tool material. The process of pendulum scribing was accompanied by registration of the acoustic emission signals. Acoustic emission was involved as a process that physically reflected alteration in the stress-strain state of the tool material.