• A novel semi-analytical multi-dimensional model integrates empirical data with mechanical theory to predict micromilling cutting forces, improving accuracy and efficiency.
• The bisection method optimizes instantaneous un-deformed chip thickness (IUCT) from trochoidal trajectories, enhancing computational efficiency and error clarity.
• An adaptive signal processing method reliably identifies tool runout from displacement and vibration signals, providing a robust foundation for force modeling.
• The approach achieves determination coefficients above 0.9 in high-speed milling tests, demonstrating its generalization capability across various machining conditions.