Demiss, Alemu (PhD)Aderaw, Awoke2018-12-282023-11-182018-12-282023-11-182016-06http://etd.aau.edu.et/handle/12345678/15338There are many causes for overheating, large stress, strain, deformation and fracture as well as tool wears of metal cutting process. velocity, feed rate, depth of cut, type of material (work piece and tool) and lubricant type takes the lion’s share those parameters: This thesis deals the effect of metal cutting variables, depth of cut and cutting speed on temperature, cutting forces, strain and von-misses stress and obtaining optimum conditions of cutting speed and depth of cut using finite element method rather than experimental techniques which makes the investigation very time consuming and expensive. At this point, finite element modeling and simulation becomes main tool. For this purpose, orthogonal milling simulation of AISI 1045 steel as work piece and un coated tungsten as tool are performed and modeled. The effects of cutting variables on cutting forces and thrust force also investigated by comparing simulation results with experimental results available in the literature. Then, thermo- mechanical and thermal analyses are performed using ANSYS software. Lastly, strain, temperature and stress distributions are investigated[8]. Here metal cutting variables of velocity 1m/s,1,5m/s,2m/s,2.5m/s and 3m/s with depth of cut of 1mm,1.5mm,2mm considered and the resulting temperature,strain,stress and total deformation of each condition is investigated. here at increasing parameters the resulting temperature is above working service temperature and the material melts.en-USStressStrainDeformationMetal CuttingFinite Element MethodThesis