This document presents a new methodology for optimizing machining performance in contour finish turning operations. It develops a computer program to calculate effective cutting conditions and tool geometry along the workpiece contour. It also formulates a methodology to predict chip side-flow for complex grooved tool inserts. Experimental databases are established and data interpolation is used to predict cutting forces, chip shape/size, and surface roughness. Finally, an optimization program is developed to determine optimal cutting conditions for contour finish turning based on predictions of machining performance.