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In this research work an attempt has been made to minimize flank wear of uncoated carbide inserts while machining AISI 1045 steel by finite element analysis. Tool wear is the predominant factor that causes poor surface finish and is responsible for the dimensional accuracy of the machined surface. The quality of component produced decides the effectiveness and competitiveness of any manufacturing industry. In this analysis, the effect of tool geometries on performance measures of flank wear, surface roughness and cutting forces generated are evaluated. Three levels of cutting insert shape, relief angle and nose radius are chosen. Taguchi’s Design of experiment (DOE) is used to design the experiments. For three parameters and three levels a suitable L9 Orthogonal array is selected. Based on the designed experiment, simulation analysis is carried out using DEFORM-3D, a machining simulation and analysis …