The stress intensity factor represents a vital parameter within the realm of linear elastic fracture mechanics. It acts as the cornerstone in determining crack propagation and evaluating damage tolerance. However, calculating this factor is a complex task. To surmount this challenge, models of the stress intensity factor for both edge and center cracks were developed using the extended finite element method. The result of this effort is the ability to calculate the stress intensity factor at the crack tip under different loads and normalized crack lengths. The accuracy of these calculations was confirmed by comparing them to results from the NASGRO method, and the optimal mesh sizes for both the crack elements and overall units were established. Further analysis, conducted through MATLAB’s regression analysis, led to the development of an empirical model. This model was found to be both simple and reliable, making it an ideal tool for engineering applications.

Titanium alloys are extensively utilized in the aerospace industry due to their exceptional properties, encompassing high specific strength and corrosion resistance. Nevertheless, these alloys present inherent challenges as difficult-to-machine materials characterized by low thermal conductivity and high chemical reactivity. The machining of titanium alloys often gives rise to elevated cutting forces and temperatures, thereby resulting in compromised machining quality and substantial tool wear. This study explores the influence of the cutting-edge shape factor on tool performance and optimizes the cutting-edge structure through finite element simulation. Remarkably, the cutting performance of the tool demonstrates significant enhancement following cutting-edge passivation. Alterations in the geometric shape of the cutting-edge after passivation exert a notable impact on the tool’s cutting performance, with a superior performance observed for shape factor K > 1 compared to alternative edge structures. Additionally, numerical simulation is employed to analyze the influence of passivation values Sγ and Sα on cutting force and temperature, which are crucial factors affecting cutting performance. The results underscore the significant impact of Sγ on cutting force and temperature. Furthermore, within the confines of maintaining an identical shape factor K, the blade segment group featuring Sγ = 40 μm and Sα = 25 μm exhibits the lowest maximum cutting temperature, thereby indicating the optimal tool design attainable through this study.