ANSYS/Implicit finite element simulation of hard turning process was performed. The modeling work covers influence of edge size on stresses distribution and estimation of flow stress data. The stress generation on cutting honed edge cutting tool in hard turning was predicted using finite element method of ANSYS/Implicit. The cutting simulation between carbide tool and AISI 1045, AISI 4345, AISI 52100 gave good predictions of stress distribution for the given cutting conditions. The obtained results from FEM indicate that the maximum Von-Misses (effective) stress acting on cutting insert with the hone tool edge while machining of AISI 4340 has the smallest value of 1607 MPa.