This paper discusses the quality of surface finish when threading titanium-based alloy under dry condition. The quality of surface finish was studied at various cutting parameters and at the two extreme stages of the machining process, i.e. at the beginning and end of the process. The objective is to evaluate the effect of a worn-out tool on the quality of surface finish. PVD-coated carbide tools were used in this study. Experiments were conducted at two cutting speeds, 35 and 55 m/min, two depths of cut, 0.2 and 0.25 mm, and a constant pitch of 2.0 mm. The tool wear and the quality of surface finish were inspected visually by microscope. The tool’s flank wear was measured gradually and machining was stopped when the flank wear reached the rejection criterion of0.3 mm. The microstructure beneath the machined surface was also evaluated. It was found that, at the beginning of machining, there was only a feed mark on the surface finish. When the machining was prolonged until the tools reached the rejection criterion, a bad surface finish was produced. Metal debris, surface cavities and a boundary crack were observed. Results show that machining with a worn-out tool can cause microstructure alteration beneath the machined surface. The selection of cutting parameters and monitoring of tool wear are crucial in order to obtain a good surface finish. Characterization of the surface finish with respect to the threading process under a dry condition would ultimately help in the development of suitable parameters for machining titanium-based alloys. Surface finish, microstructure, dry machining