A new approach was proposed to predict the cutting forces in end milling. The helical flutes were decomposed a set of differential oblique cutting edges. At every oblique cutting element, the governing equations of stress, strain, strain rate and temperature of chip through the primary shear zone were established using oblique cutting theory. The flow stress was calculated iteratively from the governing equations. Cutting forces were predicted using oblique cutting transformation into end milling. The simulation and experimental results for machining 45 steel were compared, a good agreement is observed for the different cutting conditions. The proposed method can easily be extended to other machining operations such as turning and drilling.
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