Abstract: It is very significant to investigate the milling mechanism in improving the accuracy and productivity of machining process. This article reviews the technique research progress of recent advancements in milling process. Emphasis is focused on the applications of numerical simulation technique and finite element method in error prediction and error control in milling process. Detailed reviews and comparisons are made on modeling methods for cutting force estimation, cantilever beam models for cutter deflection estimation, finite element methods for workpiece deflection estimation, calculating models for form error prediction, simulating models for material removal modeling and compensating models for form error reduction, etc. Some key techniques such as the crucial ideas, the mathematical algorithms and the simulation procedures involved in every concerned issue are discussed systematically. A perspective of the form error control techniques is also presented.

Key words: milling, cutting force model, form error prediction, error compensation, material removal, cutter deflection, workpiece deflection