Abstract: A method for optimizing machining parameters for a cutting process performed on a work piece. Finite element analysis of cutting tool and work material interaction is initially performed. Mechanistic modeling of the cutting process, using results of the finite element analysis, is then performed to provide optimized machining parameters for improved rate of material removal and tool life. Optionally, a two-stage artificial neural network may be supplementally employed, wherein a first stage of the network provides output parameters including peak tool temperature and cutting forces in X and Y directions, for a combination of input reference parameters including tool rake angle, material cutting speed, and feed rate.