The present study is mainly focused on the influence of microstructure attributes such as grain size, phase fraction and grain morphology on the machining characteristics and its correlation with the tool wear mechanisms during high-speed machining of Ti-6Al-4V under dry cutting environment. The thermo-mechanical loading at the cutting zone was analyzed in terms of the cutting forces and machining-induced sub-surface microstructure and its microhardness. The SEM-EDS analysis has been performed to correlate the microstructure characteristics with the deformation process and their consequent tool wear mechanisms. Study of built-up edge shows its substantial effect on the cutting force at higher cutting speed. Grain morphologies at the machined sub-surface depicted the severity of the deformation and explain the machining characteristics. It has been observed that the machined surface/sub-surface deformation depth increases with an increase in tool wear considering microstructural attributes. The obtained results revealed a significant correlation between microstructure attributes, cutting forces, machining-induced sub-surface microstructure and tool wear mechanisms. © 2019 The Society of Manufacturing Engineers