Common process faults during reaming operations are runout, ovality and misalignment which leads to an increase in
dynamic cutting forces during the reaming operation. This paper presents computation of cutting forces through the
mechanistic modeling with process faults. Simulated results and experimental results were obtained for different
materials and presented in the paper. For the experimentally obtained dynamic forces, process faults were manually
given on the workpiece and dynamic forces were obtained. The Deckel Maho milling machine and kistler dynamometer
are used for experimental work.