Analysis and simulation of manufacturing process require extensive and complicated computations. Nowadays, computer resources and computational algorithms reach to the state that can model and simulate the problem efficiently. One of the important processes in manufacturing is machining. In this research end-milling process which is one of the complex and wide-spread processes in machining is chosen. Most important parameters in end-milling are surface roughness and surface location errors. A comprehensive simulation software is developed to model end-milling process in order to anticipate finishing parameter such as surface roughness and errors. The proposed algorithm takes into account cutting conditions, such as feed, doc, woc, tool run out, etc. In addition, dynamic simulation module of the software can accurately model flexible end-mill tool, the milling cutting forces and regeneration of waviness effects in order to construct realistic surface texture model. The software can accurately determine the most commonly used index of surface roughness parameters such as Ra, P.T.V. and surface errors.

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