Abstract <p>Accuracy assurance of CNC machining of shaped thin-wall workpieces depends on numerous process factors, including workpiece deformation and tool wear. The problem is additionally complicated for fiber-reinforced composite workpieces due to the complexity of calculating cutting forces in their case. This creates the need for a comprehensive solution to such problems on a unified basis, which can currently be achieved through combined numerical geometric and physical modeling. The results of this modeling, as applied to milling, include calculation of the cutter path with adjustment for tool wear, voxel and finite element modeling of the worn cutter, including its surface roughness, modeling of a turbine blade workpiece made of a fiber-reinforced composite, and numerical calculation of the cutting force at a specific point on the work surface machined by the worn cutting wedge of the cutter. It is shown that the limitations of computing technology can be overcome by modeling these processes at selected points along the tool path. Modeling results can be subsequently used to adjust control programs for CNC machines.</p>