Abstract: Taking cutting force and cutting temperature as the evaluation criteria, the design and optimization of geometric parameters of the carbide four-edge flat end mills for titanium alloy processing were completed by means of finite element simulations. On the basis of the optimized parameters, the sample carbide tools were fabricated and the experiments with grooves milled by the sample tools were carried out on the Ti-6Al-4V surfaces. The influence of milling parameters on the quality of machined surface, especially the burrs at the groove edges, was investigated systematically. By comparing the machining effect and the tool wearing between the self-fabricated and commercial four-edge flat end mills under the same cutting conditions, we confirmed that the performance of self-fabricated tools was better than that of the commercial tools in many aspects, including the reduction of burr size, improvement of surface roughness, and extending the service life of tools, etc.