Five-axis milling is widely used in machining of complex surfaces parts. Part quality and productivity are extremely affected by cutting force and tool wear, especially thin-walled complex surface, such as turbine blade. Although extensive research has been conducted on cutting force and tool wear in 3-milling process, very few are on 5-axis milling and bull-nose mills. This paper presents cutting forces with various cutting conditions as well as tool wear patterns in five-axis milling super alloy, which is essential to cutting vibration and defelction analysis of thin-walled complex surfaces parts. The roles of lead angle and tilt angle in five axis milling were investigated, which provide data for NC program edit. In addition, experiments in this research proved that tool wear played affected cutting forces outstandingly.Therefore, tool wear played an very important role in tool change.