Cutting tool geometry including tool edge radius is not only important for determination of tool lifetime but also have a direct effect on workpiece surface characteristics. This geometry is created in manufacturing phase and changes occur in machining processes. In this regard, to indicate it precisely in different scales has vital importance. Most of the existing studies have focused on manufacturing parameters such as cutting speed, feed rate, depth of cut, tool geometry, and various coatings, to indicate effects of surface roughness of the machined part in two-dimensional. Limited number of studies searched the effects of tip radius in three dimensional. The purpose of this study is indicating the end milling tool geometries, their changes after milling processes and the following conditions after usage; as dimensional, form and surface deviations with modern precise measurement techniques and methods in 2D and as 3D. This paper studies the optimizing of process parameters and different coating materials which combined different tool radiuses to obtain the minimum Ra values for the end milling process of Al 7075 alloy.