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Cutting Force-Vibration Interactions in Precise-and Micromilling Processes: A Critical Review on Prediction Methods.

Szymon Wojciechowski^1,2, Marcin Suszyński¹, Rafał Talar¹

¹Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland.

Materials (Basel, Switzerland)

|August 14, 2025

Summary

This review synthesizes current research on predicting cutting forces and tool displacements in precise milling and micromilling. It provides an overview of existing models and discusses future trends in machining mechanics prediction.

Keywords:

cutting forces micromilling precise machining vibrations

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Area of Science:

Manufacturing Engineering
Mechanical Engineering
Materials Science

Background:

Precise and micromilling processes are crucial in modern manufacturing.
Existing literature lacks a consolidated review of cutting force-tool displacement interactions.
Understanding these interactions is key to improving machining accuracy and efficiency.

Purpose of the Study:

To provide a critical literature review on the state-of-the-art prediction methods for cutting forces and machining system displacements/vibrations in precise and micromilling.
To identify research gaps and current trends in the field.

Main Methods:

Review and synthesis of existing literature on cutting force and displacement models in milling.
Analysis of the relationship between geometric cutting parameters, cutting forces, and tool displacements.
Discussion of generalized analytical models for predicting forces and vibrations.

Main Results:

Presentation of current cutting force, static, and dynamic displacement models applicable to precise and micromilling.
Discussion of the interplay between cut geometry, forces, and displacements based on recent studies.
Formulation of generalized analytical models for predicting cutting forces and vibrations.

Conclusions:

The review highlights the need for comprehensive models predicting cutting forces and tool displacements in precise and micromilling.
Identifies current trends and provides an outlook on future research directions in machining mechanics.
This work serves as a synthetic resource for understanding the mechanics of precise milling and micromilling.