The formation of serrated chip will lead to vibration of machine tool, which will reduce the cutting performance of the tool and the machining quality of the workpiece. Therefore, it is necessary to analyze the formation mechanism of serrated chip, rationally optimize the cutting parameters and reduce the formation probability of serrated chip. In this paper, ABAQUS software was used to simulate the machining process of titanium alloy and the formation mechanism of serrated chip was analyzed. The influence of cutting parameters on the degree of serrated was discussed by simulation and experiment under different cutting conditions. The results show that with the increase of cutting speed and feed rate, the sawdust serration degree increases gradually. With the increase of cutting angle, the sawdust serration degree decreases gradually. The research results can be used to improve the machining quality and design the process parameters.