Abstract Prediction of chip-breaking in machining is an important task for automated manufacturing. There are chip-breaking limits in machining chip-breaking chart, which determine the chip-breaking range. This thesis presents a study of the effect of 3-D groove insert parameters on chip breaking chart. Based on the chip-breaking criteria, the critical feed rate is formulated through an analysis of up-curl chip formation for 3-D grooves. Also in order to predict chip-breaking limits, for protruded insert grooves in finish machining, analytical models are established. In the analytical models, minimum and maximum depth of cut are identified for using different chip breaking models. As well insert nose radius effects on chip thickness for small depth of cut are studied. In the end, the analytical critical feed rate model is extended to finish machining with 3-D chipbreaking grooves.