This work aims to continue the work already started by Professor Mahdi Eynian and his student Mr Hosein Khalatbari, the goal of the work is to quantify the deformation of a cutting tool during the cutting process. 

The starting research question is: How well can we predict the final depth in machining with low-diameter barrel tools? Barrel tools are a subset of a larger group of cutting tools know as circle segment machining tools, they are tools designed with large radii, resembling segments of a circle. These tools are crucial for machining complex parts because they allow for greater contact with the workpiece, enabling efficient material removal and smoother surface finishes. Their geometry reduces the number of tool passes required, in comparison to ball-end mills, increasing productivity and precision. Moreover, circle segment tools increase tool life by distributing cutting forces more evenly. As such, they are essential for producing complex components in industries such as aerospace, automotive, and mold making. This is why it is important to be able to predict the real cutting depth of such a tool, as it will be different from the input depth of cut due to the deformation of the tool, this thesis aims to be able to predict the depth of cut of the tool during machining operations.

The work methodology revolves around simulating the tool movement using its edges points, therefore a good part of the thesis will explain the steps used to extract the edges and how the method of extraction was important to the quality of the final results, as well as how were simulated both the tool rotation and the material removal in Matlab. The base data are files that contain all the coordinates of points that constitute a fine mesh constructed on the tool CAD model using Abaqus finite element software, as well as experiments realized using this tool to machine different materials, and where several parameters such as the cutting force applied were recorded, this will allow comparison between the simulated results and the experimental data. This comparison shows that the simulation isn't able to give accurate depth of cut predictions yet as it is off by around 20% but should be improved upon to take into account more parameters to get more accurate results and predictions .