The purpose of this study is to introduce the first approach of dual shear tube cutting analysis by using LS-Dyna finite element solver. Prediction of important process parameters such as reaction load, chip flow, temperature and stress distribution were considered in design of cutting tool and optimization of the cutting conditions. Johnson-Cook flow stress model and plastic kinematic & isotropic hardening were used to assign the input parameters for AISI 1045 material and the chip formation was based on effective plastic strain. A constant coefficient of friction was maintained between the tool and work piece. The simulation was carried out with different blade speeds to predict the effect on reaction load, chip flow formation and stress distribution. © 2018 Elsevier Ltd.