Development of five axis tool grinding machine and CAD/CAM systems increase tool design flexibility. In this research, investigated are cutting characteristics of ball-end mill with different helix angle. Special WC ball-end mills with 0o, 10o, 20o, 30o helix angles are designed and used in various cutting tests. Machining performance according to helix angle variation is evaluated from cutting forces, surface roughness, tool wear, produced chip shape, and vibration characteristics. The ball-end mill with 10o helix angle shows the best cutting performance due to appropriate chip load distribution and smooth chip flow. This research can be used for cutting edge geometry optimization and novel design of ball-end mill.
