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In the machining process, the machining performance which mainly refers to machined surface quality and cutting forces is hard to predict under different tool wear status. In this work, an improved case-based reasoning (ICBR) method is proposed to predict both the cutting force and machined surface roughness. With the emergence of new problem, ICBR method obtains solutions to new problem through case retrieval and reuse. In case retrieval stage, K similar cases to the new problem were retrieved using K nearest neighbor method. By means of the K similar cases, support vector regression machine (SVR) model was established to give the solution of the new problem in case of the reuse stage of ICBR method. Artificial neural network (ANN) was introduced to estimate the influence of machining parameters and tool wear on machining performance. As the ANN and SVR models contain unknown parameters, the novel particle swarm optimization algorithm was proposed to train these models for its capability of fast convergence and global optimum. The proposed ICBR method was used to predict the surface roughness and cutting force. The results showed the proposed ICBR method can give superior prediction accuracy and lower Mean square error than other popular intelligent models. Meantime, the ICBR method possesses good robustness and can be used for the actual machining process. [ABSTRACT FROM AUTHOR]