In this paper, mechanistic and finite element modeling of meso/micro end milling process with predictions of forces, stresses and temperature distributions in the presence of tool edge ploughing are presented. The finite element modeling of micro end milling without considering tool-workpiece dynamics interaction is introduced to study the effects of cutting conditions on the workpiece deformations in meso/micro end milling. Model is tested and validated for temperature and force predictions in meso/micro end milling of AL 2024-T6 aluminum.

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