Actual Problems in Machine Building. Vol. 13. N 3-4. 2026 Innovative Technologies in Mechanical Engineering ____________________________________________________________________ 34 MODERN METHODS OF IMPROVING MILLING TECHNOLOGIES FOR COMPLEX-PROFILE PARTS MADE OF DIFFICULT-TO-MACHINE MATERIALS Kisel A.G., Ph.D. (Engineering), Associate Professor, e-mail: kisel1988@mail.ru Permiakov D.S., Post-graduate Student, e-mail: daniil.klgtu@mail.ru Kaliningrad State Technical University, 1 Soviet avenue, Kaliningrad, 236022, Russian Federation Abstract The paper examines current approaches to improving milling technologies for complex-profile parts made of difficult-to-machine materials used in aerospace, power engineering, and highprecision mechanical engineering. The study analyzes the limitations of conventional machining schemes associated with intense heat generation, accelerated tool wear, vibration, profile deviation, and deterioration of surface layer quality. Recent research findings on minimum quantity lubrication, cryogenic cooling, adaptive toolpaths, ultrasonic assistance, digital twins, and intelligent tool condition monitoring systems are summarized. It is shown that the greatest technological effect is achieved through an integrated combination of methods for controlling the thermal, force, and dynamic parameters of the process. The paper concludes that integrated digital and hybrid solutions are the most promising direction for increasing tool life, stabilizing profile accuracy, reducing the probability of defects, and improving productivity in the machining of parts with complex geometry. Keywords milling, profile, parts, materials, alloys, toolpath, cooling, vibration, monitoring, wear, accuracy, productivity.
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