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Heat-resistant and high-alloy steels and alloys are difficult materials to machine. Optimizing the cutting parameters for such materials is a complex and multi-factorial technological process planning task. The paper describes the method of analysis of loading, thermodynamic and stress-strain state of a workpiece while cutting of typical representative of hard-to-cut materials (chromium-nickel alloy IN718) using finite element simulation. Influence of feed rate on cutting force and temperature in the zone of chip formation is given. The paper also analyzes the effect of cutting edge geometry on the thermal and stress state of the workpiece during cutting. Based on the conclusions about the simulation results, an analogy can be made with the processing of such materials. This will significantly reduce the time of technological preparation and decrease the cost of experimental studies.

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The achievement of high accuracy parameters and the surface layer quality of the machined surface greatly depends on the dynamic stability of the system “Machine-Fixture-Tool-Workpiece”. It is especially important for machining titanium alloys because intensive tool vibrations are generated due to the adiabatic shear phenomenon. The causes and consequences of such effects are described in the article. The paper also describes a specific method for studying the dynamic state of the cutting system of titanium alloys, based on the system integration of the classical method of the analytical description of the vibration processes arising when machining and the method of rheological simulation of the cutting process. Two important problems are proposed to be solved for the effective analysis of the system modeling results: first, it is the filtering of the noise signal with preservation of the limiting values of modeling results and maximum sensitivity using the Savitsky-Golay mathematical apparatus; second, the problem of approximation and interpolation of the filtered function of cutting parameters by Fourier transform in time.

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