PSI - Issue 81

Viktor Kovalov et al. / Procedia Structural Integrity 81 (2026) 346–352

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that PMFT significantly increases both mean and γ -percent life, indicating improved consistency and reduced probability of premature failure. The relationship between reliability and defect dispersion was further confirmed by comparing bending strength data and fractographic observations. Inserts with a high density of defects exhibited lower strength, rapid unstable crack growth, and reduced operational life, whereas inserts with fewer and more uniformly distributed defects showed stable crack propagation and increased durability. PMFT contributed to a reduction in defect dispersion, thereby increasing the overall reliability of the material. 3.4. Industrial Testing and Operational Reliability Industrial tests performed on heavy-duty lathes demonstrated that the application of PMFT to carbide inserts had a pronounced positive effect on tool performance under real production conditions. One of the most significant outcomes was a reduction in catastrophic tool failures, which are particularly critical in heavy machining due to high cutting forces and severe thermo mechanical loading. PMFT-treated inserts showed a markedly lower probability of sudden brittle fracture, resulting in reduced unplanned machine downtime and improved operational safety. The overall stability of tool operation increased, with more predictable wear behaviour and longer intervals between tool changes. These effects contributed directly to increases in both mean and γ -percent tool life. The results of the reliability analysis for turning tools equipped with T5K10 inserts obtained from comparative industrial tests of baseline and modified tools are presented in Fig. 4. The figure demonstrates an increase in the probability of failure-free operation and a reduction in the scatter of tool life after PMFT. In particular, the tool life distribution shifted toward a more stable and predictable form, reflecting improved structural integrity of the inserts. P ( τ )

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2 0,8  T

τ, min.

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Fig. 4. Results of the reliability analysis of turning tools equipped with T5K10 inserts obtained from comparative tests of the baseline and modified tools: 1 — baseline tool, 2 — modified tool.