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The observations carried out in the industry shows that companies are interested in using of “Hi-Feed” shape tools for high-speed machining of hard materials like Inconel. The design of such tools requires some experience, heat load calculations and strength using FEA techniques and tests of tools. The vibro-acoustic sensors are used during the tests. Industry prefer easy interpret results and fast methods. This paper presents the results of testing carbide cutters in two separated tasks of technology design. Authors present different shapes of vibroacoustic signals in a very similar technology operations and consequently different recommendations for design of tools. These changes of tool geometry followed by the next of work stages: 1st – analysis of the types of tool wear, 2nd – of changes, 3rd – preparation of a computer model of a new tool, 4th - carry out FEA simulation, 5th –alysis of simulation results, 6th –C programs, 7th – making of prototypes and 8th – prototype testing and monitoring tool life in clients factory. There was tested a four groups of new, unused tools. The recorded waveforms were processed to determine the envelope of acceleration, velocity and displacement signals. The geometry changes of the 4.8 mm cutters have increased their life by 40%. For the 12 mm diameter cutters this increase was also significant. The methodology, in particular the implementation of thermal load calculations and force FEM techniques, in conjunction with the results of tests based on analysis of vibro-acoustic signals proved to be very effective. Vibro-acoustic signal processing method consists in using the envelope function turned out to be enough in the studied cases.
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