AbstractThe paper presents some further developments mechanistic models for the prediction of the dynamics of cutting forces in helical end-milling operations. Since the dynamic cutting force is pro(KjrtionaJ to the chip thickness, a more accurate algorithm for calculation of the chip thickness variation due to tool geometry, run-out, spindle-tool vibration, workpiece material, and the associated cutting parameters is developed. In addition, the nonlinear force due to the process damping is also taken into account. Therefore, the model can be used to predict and analyze the dynamic cutting force accurately in helical end milling operations over a wide range of cutting conditions. A number of machining experiments were performed to verify the predicted cutting force obtained from this model. A good agreement between the predicted and measured cutting forces is demonstrated.