In this article, the effect of separation point on metal flows and the behavior of the material in front of the tool face with a rounded-edge tool are experimentally examined. The character of metal flow near the rake face has obvious significance to the partial problems of the surface finish and accuracy. Analysis of variance is used to determine the most significant parameter for the separation point height from the machined surface. As the distance between the separation point and the machined surface increased, the cutting edge radius grew. It is demonstrated through experiments that the edge radius of the cutting tool affects the machining and material flow process.