Modeling the effect of tool edge radius on contact zone in nanomachining

► We model nano-cutting with various cutting depth to tool edge radius (a/R) ratios. ► Influence of a/R on contact phenomenon and stress distributions is investigated. ► Height of stagnation zone from bottom edge of tool is increased with edge radius. ► Transitional mode from sliding to cutting is observed near critical cutting depth. ► Critical nano-cutting depth is derived for various tool edge radii.