Impact of vibrations on machining quality and tool wear during metal cutting

The purpose of this study was to comprehensively assess the effect of vibration load on the wear rate of the cutting tool, the stability of the cutting process, the thermal characteristics of the contact zone, and the quality of the machined surface during milling of metal materials. The experimental part included a comparison of three tool designs: a basic sample without damping, a configuration with a passive damper, and a tool with an adaptive vibration insert. The study was conducted at fixed feed rates, depth of cut, and rotational speed, using vibration analysis, thermal imaging, contact profiling, and dynamometric measurement of cutting forces. According to the results obtained, the use of an adaptive insert provided a comprehensive increase in the stability of the cutting process and tool life. The average radial wear was reduced by 43% (from 0.192 mm to 0.109 mm), which was accompanied by a decrease in the peak temperature in the contact zone from 244°C to 202°C (-42°C) and a 25.7% reduction in total cutting force. Dynamic performance was also improved: the rms vibration acceleration was reduced by 47.5% (from 2.45 m/s2 to 1.27 m/s2) and the integrated spectral energy was reduced threefold (from 12.6 m2/s4 to 4.2 m2/s4). The roughness parameter decreased from 1.35 μm to 0.63 μm, which reflects the improved quality of the treated surface. Morphological analysis revealed a transition from continuous to segmented chips, indicating a reduction in thermal and mechanical stresses in the cutting zone. The overall process stability index decreased from 1.00 to 0.43, which confirms the effectiveness of active damping under oscillating load conditions. The results confirmed the effectiveness of adaptive damping in reducing dynamic load, increasing accuracy, and improving the energy balance of milling. The practical value of the study lies in the possibility of implementing the findings obtained in the production shops of machine-building, aerospace and instrumentation enterprises, as well as in research laboratories involved in optimising the processes of high-precision metal machining