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This paper presents a simple analytical approach to define cut geometry of multi-pass rough milling during a free-form surface milling. The shape of in-process workpiece surface was identified using the coordinate of corner points that are found in every step of stair surface. In every instantaneous tool location, the workpiece sections that have possibility intersecting with the cutting edge were identified based on the coordinate of cutter location point. The algorithm was developed for machining using indexable flat end-mill by considering the effect of helix angle to the cut geometry. The proposed method was successfully used to determine the length of cut and generated the shape of cuts. The validation of the accuracy was carried out by comparing the length of cut measured using CAD software with those generated by the proposed approach. The results demonstrate that the proposed algorithm was accurate. Moreover, the test validated that the helix angle tends to produce larger cut.