Improvements　in　manufacturing　technologies　require　better　modeling　and　simulation　of　metal　cutting　processes.　A　fully　thermal-mechanical　coupled　finite　element　analysis　(FEA)　was　applied　to　model　and　simulate　the　high　speed　machining　of　TiAl6V4.　The　development　of　serrated　chip　formation　during　high　speed　machining　was　simulated.　The　effects　of　rake　angle　on　chip　morphology,　cutting　force　and　the　evolution　of　the　maximum　temperature　at　the　tool　rake　were　analyzed　with　the　finite　element　model.　The　simulation　results　show　that　the　segmented　chip　formation　results　in　cutting　force　fluctuation.　Although　the　segmentation　frequency　of　the　chip　increases　with　the　increase　of　the　rake　angle,　the　degree　of　segmentation　becomes　weaker　and　the　cutting　force　fluctuation　amplitude　decreases.　The　predicted　temperature　distribution　during　the　cutting　process　is　consistent　with　the　experimental　results　given　in　a　literature.　©　(2010)　Trans　Tech　Publications.