In this present research work, finite element models of cutting simulations including residual stresses and temperatures are developed to explore tool flank face on carbide tool stress growth from depositions to machining. For research, tungsten carbide tool performance in machining EN24T alloys with various cutting conditions was employed. A cohesive zone interface in a carbide tool for two dimensional cutting simulations was performed. The measurement of interface zone temperatures on workpiece was performed using infrared thermal camera. The cutting, feed, thrust forces were measured using Kristler dynamometer. The surface roughness was measured by using Taylor Hobson surface roughness tester and temperature was measured by using Infrared camera. Measurement of chip tool interface temperature is very difficult. In this work presented, the temperature and heat flux at the chip tool interface was found using heat conduction problem. The research methods employed include thermo mechanically coupled Finite Element Method (FEM) of cutting simulations, including the residual stress and temperature, tool simulation performance analysis and tool stress growth. Machining of EN24T alloy workpiece was done with a force and temperature sensor, and tool wear progress at different variable conditions in the FE cutting simulations were employed for coating analysis. The major result in cutting stresses and temperature remained dominant, compared with 2D finite element method simulations results and experimental results; both differences are satisfactory.