Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)This paper presents an investigation of nonplanar tool-workpiece interactions in free-form milling using a ball-end cutting tool, a technique that is widely applied in the manufacturing of dies and molds. The influence of the cutting speed on the cutting forces, surface quality of the workpiece, and chip formation was evaluated by considering the specific alterations of the contact between tool-surface along the cutting time. A trigonometric equation was developed for identifying the tool-workpiece contact along the toolpath and the point where the tool tip leaves the contact with the workpiece. The experimental validation was carried out in a machining center using a carbide ball-end cutting tool and a workpiece of AISI P20 steel. The experimental results demonstrated the negative effect of the engagement of the tool tip into the cut on machining performance. The length of this engagement depends on the tool and workpiece curvature radii and stock material. When the tool tip center is in the cut region, the material is removed by shearing together with plastic deformation. Such conditions increase the cutting force and surface roughness and lead to an unstable machining process, what was also confirmed by the chips collected.714198215651577Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)CAPES [PROCAD 139/2007, PROENGENHARIAS PE 27/2008]CNPq [04/2011]