Methodology for comprehensive assessment of material machinability considering processing characteristics

The paper deals with the development of a system for integrated assessment of machinability based on monitoring tool displacements and cutting temperatures. This system is characterised by its simplicity and low cost. The proposed approach to evaluating material machinability combines static and dynamic components of cutter displacements, as well as cutting temperature, each assigned specific weighting coefficients. The material machinability evaluation is differentiated for roughing and finishing operations through weighting coefficients that take into account the specific influence of each parameter on the machining results. This differentiated approach enables assessment of material machinability both from the perspective of resistance to deformation and fracture and considering specific cutting process characteristics. The dynamic displacement component serves as a diagnostic characteristic for the chip formation process (elemental, segmented, or continuous), surface roughness quality, and, when combined with temperature, for cutting tool life. Experimental results from end milling of 45 and 09G2S steels, along with VT6 and VT8M-1 titanium alloys with varying grain sizes, demonstrate the practical application of this methodology. Standardised experiments provided displacement and temperature data used to evaluate the machinability of tested materials. The results confirm the feasibility of using the proposed comprehensive indicator for assessing material machinability in cutting processes. This approach forms the basis for the development of a new comprehensive machinability assessment method that considers individual parameters and their combinations to determine technological constraints, thereby enabling process optimisation and production cost reduction.