Milling is a complex and versatile process employed to produce parts by material removal, especially in the aerospace industry. However, two phenomena—tool wear and chatter—limit the process's quality and production rate by reducing machining efficiency, accuracy and precision. As a result, industries aim to monitor these conditions in realtime. Furthermore, early identification of chatter is essential for advanced manufacturing of metal components, as it has a significant effect on surface finish and tool lifetime presenting a major limitation in increasing the material removal rate. These two challenges are frequently faced in the machining of hard-to-cut materials such as titanium alloys, which are widely used in various industries because of their high strength-to-weight ratio, exceptional corrosion resistance, and other physical and mechanical properties that are highly desired for broad applications. However, titanium alloys have low machinability, which is characterised by great variations in the cutting forces. This accelerates chatter occurrence and tool wear progress. Literature reports a variety of investigations for tool wear and chatter monitoring, but they have mostly been studied as separate and unrelated phenomena. Scholars have modelled and predicted the co-occurrence of both events, but there are some discrepancies among the findings. Therefore, to improve the quality and production of titanium alloy workpieces, this experimental study investigates the simultaneous occurrence and correlation of tool wear and chatter in milling the most employed titanium alloy, Ti6Al4V. This research aims to determine whether tool wear progress has a significant effect on chatter during the milling of Ti6Al4V.