<p>To enhance the efficacy of ball-end milling cutters in machining titanium alloys and to improve workpiece quality, a comprehensive research investigation was undertaken. A dedicated full-factor milling test platform was established to examine the synergistic effects of micro-texture and blunt edges on milling force, thermal characteristics, and tool wear, aiming to elucidate the underlying mechanisms and optimize parameters based on an ideal solution. The study’s results indicate that tools featuring mesoscopic geometric characteristics and coatings can effectively reduce milling force and temperature while extending tool life. The influence of various parameters is linked to the number of laser scans, which affects the morphology, heat-affected zone, and physical properties of the recast layer. Moreover, the implementation of micro-texture was found to decrease the tool-chip contact area, enhance the tool surface area, strengthen the mechanical anchoring effect between the coating and substrate, and facilitate heat insulation and friction reduction. The edge radius was observed to modify the area of the metal stagnation zone. A significant correlation was identified between milling temperature and force, with milling force exerting a more pronounced impact on tool wear than milling temperature. The predominant mode of wear was identified as adhesive wear, accompanied by oxidation wear.</p>