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In metal cutting practices, for a given tool material, tool geometry is a very important element and must be carefully designed in relation to the workpiece material to be machined. Patterns of tool stress are varying with input cutting conditions; however, effects of tool geometry on tool stress are not clearly understood. The load distribution on tool face is affected by the tool geometry and this causes the change of the stress distribution on the tool.

In order to optimize the geometric parameters of cutting edge for the finishing machining of 30Cr alloy steel, a two-dimensional (2D) finite element (FE) model of orthogonal cutting was built with FE software AdvantEdge. The optimized methodology of the cutting edge geometric parameters was likewise proposed based on the simulated results. Thereafter, the geometric parameters of the cutting edge were optimized based on a comprehensive criterion that combines chip deformation coefficient and tool stress. The chip deformation coefficient indirectly determines the surface roughness, whereas tool stress determines tool wear, thereby affecting the dimensional precision of the components. The rake angle ranges from 12${}^{\circ }$ to 20${}^{\circ }$, while the cutting edge radius ranges from 12$\mu$m to 20$\mu$m in the optimization process. The optimal rake angle for the finishing machining 30Cr alloy steel is 16${}^{\circ }$, while the optimal cutting edge radius is 14$\mu$m with a given relief angle of 7${}^{\circ }$.