A new cooling approach using a vortex tube and carbon dioxide (CO₂) gas has been proposed in this work. This approach is developed to minimize the cutting temperature during the machining of titanium alloy. The cutting force, surface roughness, and cutting temperature are measured by varying input flow parameters such as pressure, cold fraction, and temperature of CO₂ gas. This approach is observed to be better compared with dry cutting in reducing the cutting temperature and surface roughness. It is also observed that the cutting temperature and surface roughness are reduced with an increase in CO₂ gas pressure and cold fraction and a decrease in CO₂ temperature. Cutting force increased with a rise in the pressure and cold fraction and with a decrease in the temperature of CO₂ gas. The response surface methodology is used to predict and optimize the cutting temperature, cutting force, and surface roughness, respectively. The validation of the results is carried out by performing the experiment at optimized input parameters.