PSI - Issue 81

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ScienceDirect

Procedia Structural Integrity 81 (2026) 297–304

© 2026 The Authors. Copy from the contract: Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of DMDP 2025 organizers Keywords: heavy-duty lathes; carbide cutting tools; reliability; probabilistic modeling; tool life; readiness coeff icient; γ -percentage stability 1. Introduction The reliability of assembled cutters for heavy-duty lathes is one of the key factors in ensuring the stability of machining processes for large-sized parts in modern mechanical engineering. When turning alloy steel parts at significant cutting depths and feeds, the cutting tool is subjected to variable loads that cause complex stochastic processes of wear, chipping and destruction of the cutting part. This not only reduces the accuracy and quality of machining, but also leads to significant equipment downtime, increased operating costs and productivity losses. The modern market offers a wide range of designs for assembled cutters and carbide inserts from leading companies such as Sandvik Coromant, SECO TOOLS, Iscar, Corun , but their adaptation to the specific operating conditions of heavy-duty machine tools remains insufficiently justified. The lack of comprehensive models that take into Abstract The work studies the reliability of prefabricated carbide cutters used on heavy-duty lathes, taking into account operating conditions and typical types of failures. It has been established that, along with wear, a significant proportion of failures are caused by the destruction and chipping of the cutting part of the tool (about 61% and 18%, respectively), which significantly reduces its performance and reliability. The analysis showed the stochastic nature of cutting processes, caused by random fluctuations in the properties of the materials being processed and the tool materials, uneven load distribution and microhardness across the surface of the cutting inserts. This causes a significant dispersion of the stability period and increases the probability of catastrophic tool failure. The paper applies a probabilistic approach to assessing the structural strength and stability of cutters and develops mathematical models for determining the readiness coefficient and economically feasible level of reliability. It is shown that destructive feed can be considered as an indirect indicator of structural strength, and optimisation of the thickness of the cutting plate and the fastening structure helps to reduce the risk of failure. The results of operational and laboratory tests confirmed that reliability can be improved by improving the design of cutters, using rational fastening schemes, and introducing regulated replacement after a γ -percentage stability period. The proposed approach reduces the likelihood of cracking and sudden failure, increases the service life and economic efficiency of the tool during heavy rough machining. VIII International Conference “In - service Damage of Materials: Diagnostics and Prediction“ (DMDP 2025) Research on the reliability of assembled cutters for heavy machinery Viktor Kovalov а , Galyna Klymenko а , *, Yana Vasylchenko а , Maksym Shapovalov а , Andriy Senyk b , Evgen Reva a a Donbas State Engineering Academy, 84313 Kramatorsk, Ukraine b Ternopil Ivan Puluj National Technical University, 46001 Ternopil, Ukraine

* Corresponding author. Tel.: +38(050) 814 77 30. E-mail address: galynaklymenko1@gmail.com

2452-3216 © 2026 The Authors. Copy from the contract: Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of DMDP 2025 organizers 10.1016/j.prostr.2026.03.052