Helical milling is one of the high-performance and high-quality hole manufacturing activities with strong prospects for the automotive and aerospace industries. Literature suggests chip geometry plays a significant role in optimizing machining operations. In the present study, a mechanistic approach is used to estimate the chip geometry, cutting force and power/energy consumption concerning the tool rotation angle. Experiments are conducted at different levels of spindle rotational speed,

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... orbital speed and axial depth of cuts using 8 and 10 mm diameter mill cutters. Experimental results for cutting speed in X, Y and Z directions are measured. A hybrid approach, which combines the Taguchi method and Graph theory and matrix approach (GTMA) technique is used and optimized process parameters. The highest aggregate utility process parameters are met by 2000 rpm spindle speed, 50 rpm orbital speed and 0.2 mm axial cutting depth during helical milling of AISI D2 steel. FEM simulation is used for predicting the chip thickness, cutting forces and power consumption and also validated the optimization.