Abstract: In view of the phenomenon of flake chip formation during the ultra-high-speed cutting of Ti-6Al-4V, a typical aviation material, a high-speed cutting experimental platform based on light gas gun loading technology was developed. A light gas gun driving system with a maximum speed of 210 m/s was designed, and advanced characterization methods such as scanning electron microscopy were employed to analyze the morphological characteristics of the tool-chip interface, and evolution law of chip morphology in the cutting speed range of 0.05-210 m/s was systematically studied. Experimental results show that when the cutting speed reaches 86.5 m/s, flake chips start to form. Their formation is due to the extreme evolution of the shear band, which causes the serrated chips to fracture and separate. When the cutting speed exceeds 128.5 m/s, the shear fracture surface shows obvious characteristics of transformation from toughness to brittleness. At the same time, the temperature at the tool-chip interface rises significantly, forming characteristic molten droplets and plastic flow traces. These findings provide important theoretical guidance for the efficient and precise machining of titanium alloy components in the aerospace field, and have significant engineering application value for optimizing cutting process parameters and inhibiting the formation of flake chips.