This paper investigates a thread making process called thrilling, which performs both drilling and thread milling with one tool. A chip thickness and mechanistic cutting force model has been de-veloped for a thread milling operation with a thrilling tool. The model considers the complex geometry of a thrilling tool and the unique tool paths associated with the thread milling operation. Experiments have been conducted to validate the developed model. Comparison of the average torque and forces between ex-periment and simulation results shows that the model predicts the experimental results within 12% error.
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