Novel end mills with micro-scale structures have recently been developed to promote cutting performances with cutting forces, chip controls, and tool wears. However, the surface profiles are formed corresponding to the structures on the tool edges. The surface finishes, therefore, are worse than those of cuttings with straight edges of the end mills. This paper discusses surface profiles in milling with the structured tool and the cutter axis inclination. An analytical model is presented to simulate the surface profiles for the tool edge shape, the cutting parameters and the cutter axis inclination. Because the surface profiles are controlled in the simulation, the optimum cutting parameters are determined to reduce the surface roughness. Micro-scale nicks were fabricated on polycrystalline diamond edges with a laser machine tool. The sizes and pitches of the nicks were controlled by the laser processing parameters. The cutting tests were conducted to measure the surface profiles. The presented surface profile model was validated by comparing the simulated and the measured surface roughnesses. The surface finish can be improved in milling with the cutter axis inclination in the optimum cutting parameters.

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