An Integrated Machining Process Design Simulator (IMPDS) is developed and applied as a general tool for the design of face milling systems. The simulator includes four modules to accommodate the important factors that affect face milling operations. These modules are: a general purpose finite element program to analyze structural characteristics, a mechanistic face milling force module for both open-loop and closed-loop cutting force simulations, a machinability module to evaluate cutting process performance, and an efficient optimization module to automate the design process. The design variables, constraints, and objective function of the entire system include structural element size, shape, and weight, cutting forces and vibrations, and other machinability measures including tool life, metal removal rate, and surface finish. Several examples are included to demonstrate the capability of IMPDS in the machining system design process.

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