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An innovative approach is proposed to increase the useful life of assembled cutting tools by designing a special shape of the flank surface of indexable faceted cutting inserts (IFCIs). Calculation relationships were developed as a way to define the nature and degree of effect of blade geometry on the flank wear rate. The paper describes specifics of designing the optimal flank shape for roughing and finishing operations. Curved (convex) flank geometry is confirmed to effectively increase the tool life before reaching the maximum allowed flank wear land. An important factor for choosing the insert flank geometry and dimensions is the strength of the cutting blade of the insert. To maximize tool life with regard to the insert strength, a CAD method is developed for geometry calculation and optimization of the complex-profile flank surface. IFCI design examples featuring modified flank geometry offer improved tool life. Complex flank shape comprising a series of elementary surfaces with different geometry, is shown to be highly efficient. The results of field tests for new IFCIs in milling operations confirm the great practical value of methods for controlling the tool wear behavior through modified flank geometry.

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