While the machining of Inconel 718 has been widely studied, its cast counterpart Inconel 713LC remains underexplored, despite its relevance in high-temperature aerospace and energy components. This work presents a comprehensive investigation of dry milling behavior in Inconel 713LC, focusing on the interplay between tool wear, cutting forces, surface integrity, and chip formation across a broad range of cutting parameters. A stable process window was identified: 30–50 m/min cutting speed and 0.045–0.07 mm/tooth feed, where surface roughness remained below Ra 0.6 µm and tool life exceeded 10 min. Outside this window, rapid thermal and mechanical degradation occurred, leading to flank wear beyond the 550 µm limit and unstable chip morphology. The observed trends align with those in Inconel 718, allowing the cautious transfer of established strategies to cast alloys. By quantifying key process–performance relationships and validating predictive models for tool life and cutting forces, this study provides a foundation for optimizing the dry machining of cast superalloys. The results advance sustainable manufacturing practices by reducing reliance on cutting fluids while maintaining surface and dimensional integrity in demanding applications.

This paper focuses on mathematical modelling of cutting force with tool wear effect for milling by milling heads. With regard to a small number of experiments with sufficient accuracy, universality, speed and applicability in practice, a mathematical model based on the specific cutting force and cutting area was created. The proposed mathematical model is more refined than other models owing to more accurate calculation of the specific cutting force and cutting area. The calculation of the specific cutting force is more precise due to consideration of the influence of the cutting speed, more accurate calculation of the undeformed chip thickness and implementation of the correction factor of the tool flank wear, which has a significant impact on the cutting force. The calculation of the cutting area is achieved through more accurate calculation of the chip width as well as undeformed chip thickness. The chip width and undeformed chip thickness are refined by consideration of the straight and rounded parts of the cutting edge. For the proposed mathematical model, material constants for the workpiece material made of DIN C45 steel were obtained.

Metal machining processes require primarily cutting tool materials with high hardness, high resistance to the abrasive wear and thermal stability. The development of cutting tool materials results in advanced tool materials such are primarily ceramics, cubic boron nitride and sintered carbides which are considered to have the ability to cut hard materials. As a finishing process, the machined surface of the final product needs to control the surface quality. The quality of machined surface can be determined by properties such as surface roughness, hardness variations, micro-structural changes, residual stresses, etc. These properties belong to the surface integrity of the work piece material. The surface integrity affects significantly the mechanical properties of the parts such as fatigue limit, stress-corrosion resistance, dimensional stability, etc. This paper presents an experimental study to analyze the evolution of residual stresses in relation to the different parameter of machining. For precision milling of hardened steel, parameters are cutting speed and feed rate with a constant depth of cut. Two different cutting tool materials were used in this study, ceramic and cubic boron nitride. The results show that residual stresses near the machined surface of hardened steel are suitable for compressive stress.

One of the problems in machining Al alloys represents machinability of these materials. Machinability is a characterised by several characteristics. One of these characteristics is a cutting temperature. This paper is focused on the effect of selected modifiers in AlSi7Mg0.3 alloy on this temperature. Several variants of this material modified by strontium, calcium and antimony are used. All these materials are compared with non-modified alloy. Moulded castings of non-modified alloy and for each modified variant were made. Gravity-die castings into a metal mould with a thermal insulation were used.

One of the main problems in machining Al alloys represents built-up edge formation. This paper is focused on the effect of selected modifiers in AlSi7Mg0.3 alloy on built-up edge formation. Four variants of castings modified by strontium, calcium and antimony are used. All these alloys are compared with non-modified alloy. Built-up formation leads to the increasing of surface roughness for both types of built-up edge - unstable or stable. If unstable built-up edge is produced, surface roughness increases enormously. Therefore the research is focused on surface roughness in different cutting conditions. There were moulded castings of non-modified alloy and for each modified variant. Gravity-die castings into a metal mould with a thermal insulation were made.

Aluminium and silicon alloys are widely used in practice. But there is increasingly more emphasis plac ed on the research and development of these materials. The ai m of this article is to analyse modified aluminium alloy AlSi7Mg0.3. The paper is focused on the effect of p articular modifiers in AlSi7Mg0.3 alloys on built-up edge formation in machining. Four variants of castings (unmodified alloy and alloy modified by chemical elemen ts strontium, calcium and antimony) were used. All alloys were compared with non-modified alloy. There were mo ulded castings from each modified variant and the casting of non-modified alloy. It was casted using a gravi ty-die casting into a metal mould with a thermal insulation.

Jan Brajer, Jan Mádl, Roman Švábek, Zdeněk Pitrmuc ,Danijela Rostohar, Pavel Zeman , José Luis Ocaña Department of Machining, Process Planning and Metrology, Czech Technical University in Prague, Technická 4, 166 07 Prague 6 Dejvice, Czech Republic E-mail: J.brajer@fs.cvut.cz HiLASE Centre, Institute of Physics ASCR, Za Radnicí 828, 25241 Dolní Břežany, Czech Republic E-mail: brajer@fzu.cz Centro Láser UPM (Universidad Politécnica de Madrid) Ctra. de Valencia, km. 7,3. 28031 Madrid. Spain. E-mail: jlocana@etsii.upm.es

Lead is traditionally used for completing free-machining materials. This paper deals with newly developed lead free copper alloys. Unfortunately, lead affects the haematological and nervous system. Therefore, materials containing lead represent one of the greatest environmental problems in world production. Research Material Institute in Panenske Brezany (CZ) developed new environmentally friendly cooper alloys. Machinability of these materials was tested at the Department of Machining, Process Planning and Metrology CTU in Prague. Some of the research results related to the machinability from the viewpoint of chip forms, surface roughness, cutting temperature, cutting time in drilling with constant feed force, and forces in cutting are presented.

Aluminium and silicon alloys are widely used in practice currently, e.g. in car industry, aircraft industry or in civil engineering. Hence there is increasingly more emphasis placed on research and development of silumins. The aim of this paper is to analyse aluminium alloy, namely the alloy AlSi7Mg0.3. This paper is focused on the effect of particular modifiers and heat treatment on the selected properties of the alloy, especially on structural transformations caused by various modifiers, hardness measurement (Brinell method) and microhardness testing (Vickers method). Four variants of castings (unmodified alloy and alloy modified by chemical elements - strontium, calcium and antimony) were tested. All alloys were compared to the cast of pure aluminium (Al 99.8%). There were moulded four castings from each variant and two castings of pure aluminium. It was casted using a gravity-die casting into a metal mold with a thermal insulation - except of pure aluminium (without thermal insulation).

Cutting tool wear monitoring is one of key problems in automation of machining processes. Apart from the cutting tool wear monitoring for the cutting tool change and cutting tool failure, cutting tool wear monitoring may be one of the components for the adaptive control of a machining process. This paper is focused on the design of turning cutting tool wear sensors of the system flap - jet principal with increased extend. On the geometric principles in cutting with a turning cutting tool, the relations among the output of jet mouth, clearance angle and cutting tool wear were expressed. Two variants of turning cutting tool sensors were designed and experimentally verified. The results of experiments have proved the possibility to apply cutting tool wear sensor of the system flap - jet principal with increased extend in practical use.

Precision hard machining is a topic of high interest at present. Surface integrity requirements increase. Precision machining may substitute some abrasive operations with some advantages of precision machining over the abrasive machining. But, the availability of hard machining over abrasive machining can also lead to economic advantages. Manufacturing processes, machine tools, cutting tools, tool changes, cutting conditions, etc., are nowadays usually determined intuitively, very often non-professionally, without careful analysis and economic calculation. The determination of cutting conditions is very important aspect of the total optimisation of manufacturing processes. Hard machining is possible to realise by different cutting materials, especially by cubic boron nitride, ceramics and some types of sintered carbides.

In this paper the effect of factors entering into the optimisation of cutting conditions and affecting production costs in turning is analysed. Optimisation of cutting conditions affects every manufacturing company in the field of machining, and represents an important area of the economy these enterprises. The aim of the research was to determine the size of the influence of input factors on the results of the calculation of the optimisation of cutting conditions using inserts in turning. Each constant is moving at a definite recommended range of values depending on various conditions. If we find out what the most important input factors most affecting the calculation of the optimisation of cutting conditions, we are able to focus primarily on the following factors. Influences of selected factors on costs are presented in graphs showing their interdependence. The influences of the input factors received from overall analysis were categorized by importance and created a list containing three groups significance of individual factors. According to the created groups a company can more easily focus on the parameters that most affecting the cost of turning, thereby improving the selection of specific technical, economic or time values in the company.

Machinability of materials is evaluated by different criteria. The basic evaluative criteria are based on tool wear. However, there are other criteria, for instance chip formation, cutting temperature, forces of cutting, etc. Machinability for different criteria depends on many factors, of which the most important is the chemical composition of the material. It is possible to divide machinability tests into two groups: Long-term tests and short-term tests. Short-term machinability tests are less objective than long-term ones, but they have the advantage of short duration and lower material consumption. This paper is focused on the experimental determination of the effect of chemical composition on the machinability of aluminium alloys. For testing three different short-term tests were used. The results were evaluated by correlation coefficients. All used tests led to the same results.

In evaluating larger number of measurement data, it is proper to analyze them statistically. It is important to determine the effect of measured data number on the experiment results. This paper is focused on the determination of the effect of the basic file size (data obtained in the experiment) on the final measurement results. In milling the cutting inserts of sintered carbide (SC) were used. The same cutting conditions (depth of cut, feed, cutting speed) and were used. The cutting inserts wear was measured after the same cutting time. At the beginning of experiment 120 measured data (edges) were used. Number of measured data was gradually increased (to 240, 360, 480, 600, 720, 840, 960 and 1080). Totally 9 basic files was obtained. In the conclusion of the paper lists of all results are presented together, with their mutual comparison and prediction of the possible development of tool wear at higher number of cutting edges.

Precision machining and especially hard machining is a topic of high interest at present. Surface integrity requirements increase. Hard precision machining may substitute some abrasive operations. There are some advantages of hard cutting over the abrasive machining. Abrasive machining has traditionally performed the finishing process of hardened steel. But, the availability of hard and super hard cutting tools enable the machine tools to reach surface quality of hard machining like to those obtained in grinding processes. A surface is not only a geometric entity but also a layer with its own structure and properties. These properties are affected by many factors, e. g. by cutting temperatures, friction, deformations in the primary deformation zone and the surface layer of the transient (machined) surface, by cutting tool geometry, work hardening, cutting environment, etc.

Precision machining of soft and hardened materials is a topic of high interest to substitute some traditional operations. This paper deals with some aspects of the precision machining of notches. All machining processes result in changes of surface layer properties. There are changes in residual stresses, in harness, changes in material structure etc. and also in surface accuracy and surface roughness. All these characteristics may affect fatigue cracks in machined parts.

Concurrent engineering plays an important role in manufacturing. Cooperation among all factors relating to the realisation of products is now necessary. Production costs represent about 40% of the selling price of products and therefore design for production and for other aspects is very important

Utilization of force signals to a chieve on line drill wear monitoring is presented in this paper. After consulting the available literature it is obvious, that only some features of force component are proposed for drill wear monitoring. The really important task in drilling operations is to avoid catastrophic failure. It is desirable to make the most economic use the cutting tool without reaching catastrophic failure. Traditionally, the usual approach to tool monitoring the drilling was to the detect breakage as fast as possible and avoid overloads in the machine tool. These strategies are not enough to ensure the optimum economic performance of the machining process. Therefore, the primary objective of this lecture assesses the feasibility of using force signature analysis as means for monitoring tool wear.

The paper describes some results of the research into plastic deformation and cutting temperature in high speed milling of aluminium alloy 2024-T351. The effect of cutting speed and feed on selected parameters in chip formation has been studied.The experimental and simulation research was carried out by with sintered carbide inserts. It was focused on chip fori-nation, plastic deformation and the cutting temperature. The plastic deformation was studied by means of the chip roots, which were obtained with a quick stop device. The cutting temperature was measured by the tool-workpiece thermocouple. The AdvantEdge 4.2 simulation software, based on the Finite Element Method (FEM) and on the material modelling, was used for the simulation study.