Titanium alloy has dominated in mechanical-based industries due to its superior tensile strength, toughness, and corrosion resistance. This research involves the development of a wear model integrated with the FEM model. A numerical study and experimental work were conducted to variant tool nose radius, cutting speed, and feed rate in the machining of titanium alloy. The machining operation was properly simulated using Deform2D commercial-based software to predict the cutting force, tool wear, and cutting zone temperature. In addition, the same output response was assessed in the experimental technique by employing all geared lathes. In both the experiment and simulation conditions, the least cutting force was produced at the lowest feed rate and the smallest nose radius. It was noticed from the data that the cutting zone temperature at the cutting zone region was raised with an increase in the tool nose radius. Utmost tool wear was recorded at the minimal tool nose radius and minimum feed rate. Cutting speed plays a vital function in the evaluation of tool wear and nose radius in the prediction and assessment of cutting tool force and tool interface temperature. Tool wear study and surface morphology were fully explored with the assistance of SEM images

Keywords: Titanium, Tool wear, Cutting force, Deform 2D, Tool tip temperature, Simulation