The purpose of this study was to develop finite element simulation approach of dual shear tube cutting analysis by using LS-Dyna finite element solver. A fracture model was great concern when it comes to as a chip formation and the simulation of localized shear bands that was takes place in a serrated chip formation. The design of cutting blades and optimizations of the cutting conditions were done based on reaction load and chip flow behavior of work piece material. Johnson-Cook flow stress model was used to assign the input properties for tube material and the chip formation was based on effective plastic strain defined in this model. A constant dry coefficient of friction was maintained between the tool and work piece to maintain real conditions in FEA. The simulation was done at different blade speeds, tube material, tube thickness and blade thickness to predict the effect on reaction load, chip flow formation and stress distribution. The servo control prime mover was selected based on productivity and load requirements. The results between analysis and experiments were compared. The work is further extended to prototype development. © 2018 FISITA. All rights reserved.