5-axis milling operations are common in several industries such as aerospace, automotive and die/mold for maching of sculptured surfaces. In almost all of these operations, the dimensional tolerance integrity and surface quality are of utmost importance. Part and tool deflections order cutting forces may result in unacceptable part quality. Process models can be used to determine the proper or optimal milling conditions for required quality with higher productivity. Majority of the milling models have been developed for 3-axis operations, even the ones for ball-end mills. In this thesis, a complete kinematics and force model is presented for 5-axis milling operations using ball-end mills. The effects of lead and tillt angles are included in the model, and presented in the thesis. Tool deflections due to the cutting forces are also formulated for 5-axis milling. Model predictions for cutting forces are compared and verified by experimental results
