This study are focused on the deformation zones occurring in the work piece in a machining process and the corresponding cutting forces. The fully coupled thermo-mechanical FE-model for orthogonal cutting, developed in  is utilized. The work piece material is modeled with Johnson-Cook plasticity including damage formulation. Simulations for different feed depths were performed. The cutting forces, the chip thickness ratio and the deformation widths were determined experimentally by the quick-stop images and a force measurements. The results from the simulations have been compared to experimental data for the cutting forces and the chip thickness ratio as a function of the theoretical chip thickness.