Thin-walled parts are widely used in many industries. In the milling of thin-walled parts, the machining accuracy is highly affected by the milling method on which the milling force depends. Milling force is one of the main characteristics of the milling process. In the analysis and comparison of the milling forces among machining methods applied, it is essential to evaluate the total force and its components, as the individual components directly affect the elastic deformation of the thin-walled part. The rearrangement of the milling force components by overlapping is the main advantage of the method presented. In addition, this method allows the formation of complex microstructures on the surface, which is essential for ensuring their tribological properties. The overlapping permitted method for reducing the milling force component and therefore in stress without additional fixture support or significant equipment parameters change. The modeling results evaluation of the generated force components and stress, depending on the degree of overlapping method and the comparison with the conventional one, are presented with the equal input milling parameters. The relationship between the aftercuts geometry and the material removal rate is established. The milling force decrease at 75° and 60° lead angles is observed. The research aim is to study the formation of scallops using the overlapping method on thin-walled parts surfaces and analyze the response of their structure to achieve a more uniform surface finish.