Accurate　modeling　of　milling　forces　and　tool　vibrations　is　crucial　for　the　simulation　of　milling　processes.　Taking　into　account　the　nonlinear　dynamic　regenerative　effects　of　the　milling　system,　a　boundary　geometric　method　for　simulating　the　milling　process　is　proposed　by　superimposing　the　changes　in　tool　position　caused　by　tool　vibrations　and　tool　runout　onto　the　milling　trajectory.　The　physical　features　of　the　tool　teeth　and　workpiece　can　be　characterized　with　the　micro　segments,　in　which　the　identification　of　the　tool-workpiece　cutting　contact　area　and　calculation　of　the　instantaneous　undeformed　chip　thickness　can　be　obtained　through　the　geometric　relationships　between　these　micro　segments.　And　the　material　removal　from　the　workpiece　is　accordingly　achieved　by　scanning　the　cutting　area　with　the　tool　teeth　micro　segments.　On　this　basis,　the　micro-element　integral　method　is　used　to　calculate　the　milling　forces,　and　then　the　dynamic　equation　of　the　milling　system　is　established,　with　the　tool　vibration　displacements　solved　using　the　fourth-order　Runge-Kutta　method.　To　verify　the　reliability　of　the　simulation　model,　experiments　are　conducted　to　measure　the　milling　forces　and　tool　vibration　displacements.　The　experimental　results　show　that　the　milling　force　and　tool　vibration　displacements　can　be　accurately　predicted　by　the　established　simulation　model,　with　relative　errors　of　less　than　10%,　thereby　laying　a　foundation　for　subsequent　digital　research　on　milling　processes.　©　2025　Chinese　Mechanical　Engineering　Society.　All　rights　reserved.