The study is devoted to the development and testing of technological principles for the manufacture of solid end mills from ceramics based on a powder composition of α-SiAlON, β-SiAlON, and TiN additives, including spark plasma sintering powder composition, diamond sharpening of sintered ceramic blanks for shaping the cutting part of mills and deposition of anti-friction Si-containing diamond-like carbon (DLC) coatings in the final stage. A rational relationship between the components of the powder composition at spark plasma sintering was established. The influence of optimum temperature, which is the most critical sintering parameter, on ceramic samples’ basic physical and mechanical properties was investigated. DLC coatings’ role in changing the surface properties of ceramics based on SiAlON, such as microrelief, friction coefficient, et cetera, was studied. A comparative analysis of the efficiency of two tool options, such as developed samples of experimental mills made of SiAlON/TiN and commercial samples ceramic mills based on SiAlON, doped with stabilizing additives containing Yb when processing nickel alloys (NiCr20TiAl alloy was used as an example). DLC coatings’ contribution to the quantitative indicators of the durability of ceramic mills and the surface quality of machined products made of nickel alloy is shown.

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It is recommended to use high-speed milling to maintain an effective material removal rate and the required cutting-edge geometry. However, on the other hand, high speed increases wear, so the surface of the cutters is modified by deposition functional coatings. The wear of end mills made of CTS12D and H10F tungsten carbides during the high-speed processing of aluminum A97075 (B95T1) was compared. To increase the durability of the tools, well-proven technologies for deposition diamond-like and polycrystalline diamond coatings in microwave plasma with different film structures, which were determined by the coating growth conditions, were used. The milling cutter corner was mostly worn out, but the nature of the wear had its characteristics. It was revealed that at a forced cutting mode of about 1000 m/min, cutters made of CTS12D alloy with a nanocrystalline diamond coating with a “cauliflower” structure and with a diamond-like film showed 10% higher resistance. The primary wear mechanism was adhesive. Images of worn cutting edges were obtained using a 3D optical digital image processing system.

The shaping of the toroidal cutting section of end mills is considered. Methods are devised for selecting the positional parameters in shaping the helical

Four surgical osseodensification drills with different geometric parameters were designed and manufactured from martensitic stainless steel (equivalent to AISI 420) with a wear-resistant titanium nitride (TiN) coating applied by physical vapor deposition (PVD). For the experimental study, bone samples (blocks) were prepared from cattle ribs, corresponding to C. Misch’s D3—D4 bone type, which is commonly found in the distal jaws. The processed samples were divided into groups according to the previously assigned surgical drill number. After every 4th osteotomy, an optical assessment of the cutting edge wear was performed using a scanning electron microscope and the change in bone tissue temperature was determined using a K-type thermocouple. Our experimental study on cattle ribs confirms the complex influence of the osseodensification drill geometry on the heating of bone tissue and its density estimated by Hounsfield unit (HU) value during the preparation of a dental implant bed using a sequential drilling protocol with a minimal step of increasing the working diameter of the drill. Surgical drills made of AISI 420 steel with a TiN (PVD) coating showed no wear after 24 osteotomies, which is comparable to the reference Densah drills. Drill with the largest clearance and helix angles, provides the best thermal conditions during the osteodensification procedure. Drills with a clearance angle α =20° provided a 2—6 times higher densification increase than drills with an α=6°. Drills with α=20° increased bone density by 34—51%, while those with α=6° increased density by only 7—20%. Further studies to refine and validate the obtained models of functional relationships, including the use of experimental drills using other drilling protocols, seem relevant.