Development of a Special Milling Cutter Design for Combined Machining of Difficult-to-machine Austenitic Steels

Abstract

The aim of the study is to develop a tool design that combines preliminary frictional action with mechanical cutting, as well as to assess the reliability of the structure through strength analysis of the fastening elements. The article presents an analysis pf the machining challenges associated with industrially used austenitic Hadfield steel, along with a review of existing processing technologies. A special combined milling cutter design has been developed to improve the machining efficiency of difficult-to-machine austenitic materials. The distinctive feature of the cutter is the combined design of its working part, consisting of fictional and cutting sections. A strength analysis was carried out for the bolts securing the frictional part of the cutter. It was established that at a cutter diameter of 186 mm, f rotational speed of 1500 rpm, and a drive power of 7.5 kW, the stresses in the fastening elements do not exceed the permissible values. The proposed design ensures structural reliability, improved machining productivity, and reduced tool wear. The research presented in this article was carried out within the framework of a project funded by the Science Committee of the Ministry of Science and Higher Education of the Republic of Kazakhstan (Grant No. AP26199283).