The problem of increasing the tool durability (service life) when machining hard-to-machine materials is one of the major practical problems of modern mechanical engineering. This paper aims to improve the wear resistance of modular disk mills using the pre-processing method. Second-order rotatable planning was applied for the experimental study of the pre-processing of modular disk mills. Experimental research on the pre-processing of modular disk mills was carried out on a vertical milling machine XH950A when milling a workpiece made of steel 45. It was revealed that the increase in pre-processing modes up to specific values (f = 60 mm/min; $v_c$ = 17 m/min; t = 6 min) on the tool durability period has a positive effect. At the same time, the tool durability period was increased up to T = 155 min. Tests of the machined modular disk mills were carried out in the conditions of the laboratory base to determine the durability period. After pre-processing at different modes, each modular disk mill was used to machine the workpiece until wear signs appeared on the cutting edge. At the same time, the time was recorded to determine the durability period. It was found that the optimum mode of tool preliminary pre-processing provides the best deformation and thermal conditions for hardening the tool cutting part. As a result of modeling with the ANSYS 2024 R1 program, it was found that a hardened layer is indeed formed on the cutting part of the modular disk mill after pre-processing. The results obtained show the possibility of using the preliminary pre-processing method to improve the wear resistance of other metal-cutting tools.

Cutting fluids play a crucial role in machining processes by cooling the cutting tool and workpiece, reducing friction at the tool-workpiece interface, and facilitating chip removal from the cutting zone. The primary objective of cutting fluid application is to minimize heat generation and...

This study investigates a method for the rotational turning of external cylindrical surfaces with a particular focus on evaluating the quality of the machined surface and its stress state during the turning of 45 steel, using experimental methods and the Finite Element Method (FEM). The influence of the cutting modes on the quality indicators during rotary turning was analyzed, and their optimal values for the processing of steel 45 were determined. The results indicate that an increase in the spindle speed has a positive impact on the roughness of the machined surface, but a negative effect on hardness. Increasing the feed rate has an ambiguous impact on the quality indicators of the machined surface: it improves the roughness but reduces the hardness. With an increase in the cutting depth, both quality indicators deteriorate. In addition, using the ANSYS/LS-DYNA (Ls Pre-Post) software package, the stress-strain state of the steel 45 workpiece was calculated, and the temperature change in the cutting zone, in the chips, and on the machined surface during rotational turning was determined. This revealed that the maximum equivalent Mises stress is 1.1 MPa and the maximum temperature in the cutting zone is 287 °C. It was observed that when the cutting force fluctuates within the range of 4.8 kN-5.1 kN, the vibration occurring in the cutting zone is reduced. The results of this study indicated that rotary machining allows for increased feed, depth, and cutting speed without critical tool wear, which directly increases the productivity. It also reduces the tooling, energy, machining time, and rework costs, resulting in significant economic benefits.