Abstract
In this research paper, finite element models for drilling and milling were built respectively for a new chamfer drill tool and simulation results obtained for the best combination of geometric parameters. An orthogonal milling test experiment was conducted using a CNC vertical milling machine to obtain the cutting force and surface roughness. The rake angle of 15°, relief angle of 4°, base circle of 60% and helix angle of 0° produced the minimum milling force during the simulation test. A comparison of the simulated results and the experimental results gave an error limit of 4% indicating that the accuracy and reliability of the simulation are better. The experimental results showed that the chamfer depth of 1 mm, cutting speed of 120 m/min and feed of 0.1 mm per tooth exhibited the best combination of cutting parameters in terms of low cutting force and surface roughness.
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