A　comprehensive　3D　finite　element　simulation　study　has　been　conducted　to　investigate　the　tool　temperature　distribution　along　cutting　edge　and　chip　formation　during　drilling　of　Ti6Al4V　alloy　by　using　commercial　finite　element　software　Abaqus/Explicit.　The　Johnson–Cook　material　constitutive　model　and　material　failure　criterion　were　implemented　across　the　formulations　to　achieve　the　tool　temperature　and　chip　formation　in　the　drilling　process.　The　effect　of　different　mesh　sizes　on　simulation　results　was　also　analyzed.　To　assess　and　verify　the　accuracy　of　the　simulation　model,　the　corresponding　experiment　studies　were　carried　out　by　measuring　the　thrust　force,　tool　temperature,　and　chip　morphology.　Compared　results　show　that　the　predicted　thrust　force,　temperature　distribution,　and　chip　morphology　are　in　good　agreement　with　those　tested　from　experiments.　According　to　the　combination　of　both　simulations　and　experiments,　it　can　be　not　only　found　the　whole　varying　pattern　of　the　thrust　force　but　also　reveal　that　the　temperature　decreases　from　drill　center　to　outer　corner　along　the　primary　cutting　edge.　In　addition,　it　can　provide　a　more　detailed　and　profound　knowledge　about　chip　formation.　All　these　are　assumed　to　be　recommendations　for　the　optimization　of　tool　geometry　and　drilling　processing.　©　2022,　The　Author(s),　under　exclusive　licence　to　Springer-Verlag　London　Ltd.,　part　of　Springer　Nature.