The goal of this work was to develop a series of guidelines to improve the efficiency of exit window miliing in well bore lining tubes for oil and gas production. Having assessed the suitability of PCD, PCBN and carbide cutters for the machining of duplex stainless steel using a novel, eccentric face-turning arrangement with tubular workpieces, near-optimum cutting conditions have been established. The same cutting experiments provided accurate tool force data which was mathematically modelled so as to permit the calculation of forces for un-deformed chip cross-sections of arbitrary geometry - a fundamental requirement for the geometrical modelling of the exit window milling process.
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