International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

This article presents a study of the influence of cutting edge rounding on the wear of monolithic milling tools using the finite element method (FEM) and DEFORM 3D software. After manufacturing by grinding, monolithic milling tools have considerably sharp cutting edges that are prone to breakage and chipping. Industrial practice and cutting edge zone theory recommend edge preparation to create a defined cutting edge radius. The optimal radius value depends on the machined material, cutting conditions, and other factors, and remains unclear. This study investigates the influence of the cutting edge radius on tool wear using 3D FEM simulation with the Usui wear model, which is considered suitable for machining processes. Initial simulations with sharp cutting edges were performed to determine the sensitivity of wear predictions to the Usui model constants. Subsequently, different cutting edge radii were simulated under identical cutting conditions. The simulation results demonstrate the relationship between cutting edge radius and wear progression. The findings provide guidelines for selecting suitable cutting edge preparation parameters to minimize tool wear when milling with monolithic tools.

University-level instruction in technically oriented subjects requires effective and illustrative tools for visualizing complex manufacturing processes. Academic staff in engineering disciplines generally possess solid knowledge and experience in using CAD systems for geometric modeling, which are a core component of modern technical education. However, the use of graphical systems for creating animations remains underutilized in many curricula. This paper presents an approach that builds on existing CAD models, created in widely used engineering software (e.g., SolidWorks or Inventor), and transforms them into professional multimedia teaching aids using the opensource software Blender. Using the example of cold drawing of seamless tubes, the complete process is demonstrated — from model creation and export to the animation of material deformation. Once a 3D model has been developed, only a small step is required to create a visually compelling and pedagogically valuable animation. Such multimedia outputs enhance the educational process, make the learning experience more attractive and engaging for students, and facilitate deeper understanding of complex technological phenomena. The article concludes with methodological recommendations for university educators on how to effectively integrate multimedia tools into engineering education with minimal additional effort.

High-speed machining (HSM) significantly influences the thermal dynamics of the cutting process, particularly in the toolworkpiece interaction zone. At elevated cutting speeds, the reduced tool-workpiece contact time minimizes heat transfer to the workpiece, concentrating thermal energy in the cutting zone. This results in localized material softening, reduced cutting forces, and enhanced process efficiency. This study investigates the thermal effects of HSM by experimentally turning C45 steel using a cubic boron nitride (CBN) tool at cutting speeds ranging from 800 m/min to 1800 m/min. Cutting forces were measured and analyzed in conjunction with temperature distributions within the cutting zone and tool. The experimental results were compared against predictions from the analytical Oxley machining model and numerical simulations using DEFORM software. The analysis revealed the dependence of cutting speed on cutting zone thermal properties, providing insights into material behavior under high-speed conditions. Furthermore, the study identified optimal cutting speeds that balance thermal effects and cutting process stability. These findings contribute to the definition of appropriate high-speed machining parameters, ensuring effective heat dissipation and stable tool performance.