This book has aimed to give in detail knowladge about numerical modeling technique to examine the residual stresses induced by orthogonal machining in the finished work piece. The finite element method is used to simulate and analyze the residual stresses induced by a orthogonal metal cutting process. A Dynamics explicit time integration technique with Arbitrary Lagrangian Eulerian (ALE) adaptive meshing Finite Element Method (FEM) is employed to simulate the model. The Johnson-Cook material model is used to describe the work material behaviour and fully coupled thermal-stress analysis are combined to realistically simulate high speed machining with an orthogonal cutting. Finite Element modelling of Residual stresses and resultant surface properties induced by round edge cutting tools is performed as case studies for high speed orthogonal machining of 20NiCrMo5 steel.Both 2D and 3D modeling technique for orthogonal machining has describe in this book.Models are well validated with experimental results.This book is useful in advance level research on numerical modeling of metal cutting operation.