Generally cutting tools performance are studied by FE analysis or experimental tests. So Is there any method to investigae the tools performance apart from the above mentioned approaches?
I think is possible to study the edge of cut measuring the cutting forces. Similar edge shapes with differents coatings, can produce differents cutting forces. Normally, when the cutting force at equal cutting conditions, gives smaller forces, the cutting tool is better, and the edge takes longer.
in case of ductile material study and investigate chip formation. For good surface finish and machining process, a continuous chips are formed. Also, here w/p diameter also plays a vital role. Other than FE and experimental, investigating the formation of chip for different tool and then correlating with machining parameters can also look upon.
The idea from Agari, is very important. If you want you can collect chip during differents experimental test and clasified the shape with the ISO 3685 standard. Always chip "speaks" about the process.
For stress distribution on the tool there is no other method than FEM to do so. But for stress distribution on shear zones, I would suggest Slip-line technique. But you should be really careful for application of this method on different material because of its assumptions. Look at:
I think is possible to study, Which type of alloy for the cutting tool is exactly suitable for the product that want to produce, for Example to check the hardness for cutting tool and product, and geometery of the cutting tool
during turning operation, there are two possible cases one is formation of chatter or the other no formation of chatter. during chatter formation, there is vibration and more heat developed in the machined surface and in turn for the chip. due to this discontinious chips are formed and in turn effect cutting tool. For no formation of chatter, the chips formation maybe continious and does not effect much on tool. I think this is a small idea where u can llok upon