Introduction Finite Element Method analysis employs a number of finite points called nodal points covering the domain of a function to be evaluated. The subdomains within these nodal points are called finite elements [1]. Thus, the entire domain is a collection of elements connected at their boundaries without gaps. Each element connected to another by its nodes. The use of single point cutting tool in metal machining has been employed for generations in the production of components of various shapes, sizes and design specifications. Metal machinists have over time endeavoured to understand the mechanics of plane-strain orthogonal cutting to develop understanding of all machining procedures. The best analytical methods of orthogonal metal machining were first developed and presented by Merchant [2], who introduced the concept of the shear angle. This was followed by Lee and Shaffer [3], who proposed an analytical model using slip-line theory. Both models endeavoured to explain what takes place at the chip-tool interface. More accurate and sophisticated models have been developed lately with the advent of computer by incorporating the features of friction [4], work-hardening, strain-rate [5, 6] and temperature distributions [7]. In this study the finite element model used for the plane-strain orthogonal metal cutting simulation is based on the updated Lagrangian formulation in AdvantEdgeTM5.911 simulation software. The plane-strain supposition isthat in real metal cutting processes the width of cut is at least five times greater than the depth of cut and this is presumed to establish a reasonable approximation, since the chip is produced under nearly plane-strain conditions.