In this work, we performed a study and developed the design of through-cutters that provide accelerated heat removal from the cutting zone with external turning. Using SolidWorks Simulation engineering analysis and SolidWorks Flow Simulation gas-hydrodynamic analysis modules as a research tool, we created a basic 3D model of a precast cutter and carried out a thermal analysis of the transition process to determine the distribution of temperature fields in the body of the cutter throughout time during the cutting process. After that, we made changes to the design of the cutter, specifically, created a cavity in the holder body in which the copper core was placed. We then re-performed the studies described above, which showed that when using a copper core, the temperature in the cutting zone decreases by 246 °C within 15 minutes from the start of the work. To obtain a greater effect, we added a hole in the copper core and used air cooling, which allowed reducing the temperature in the cutting zone by 313 °C.

The article studies the influence of design solutions on heat sink when turning with a cutter with internal air-cooling. A cutter design with increased heat sink has been developed. This design allows to significantly expanding the scope of use of cutters with internal air-cooling instead of traditional cutters with coolant.

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In this study, we investigate the reasons for the decrease in the durability of cutting tools with diamond-like carbon coating. We formulated a previously unexplored assumption that the destruction of the coating may occur due to the dissimilarity of the thermal expansion coefficients of the latter and the substrate material. To verify this assumption, we developed a special technique based on the theory of elasticity and carried out a study of several end mills and turning tools made of different materials. The results of our research confirm the validity of the hypothesis. We further propose methods of combating the discovered reason for the decrease in tool life.