For qualitative prediction of chip morphology and quantitative prediction of burr size,2D and 3D finite element (FE) based turning models have been developed in this paper.Coupled temperature-displacement machining simulations exploiting the capabilities ofAbaqus® with a particular industrial turning insert and a newly proposed geometricalversion of this insert have been performed. Limitations of 2D models in defining the chipmorphologies and surface topologies have been discussed. The phenomenological findings onthe Poisson burr (Side burr) formation using 3D cutting models have been highlighted.Bespoke geometry of the turning insert has been found helpful in reducing the Poisson burrformation, as it reduces the contact pressures at the edges of tool rake face-workpieceinterface. Lower contact pressures serve to decrease the material flow towards workpieceedges (out of plane deformation). In contrast, higher contact pressures at tool rakeface-workpiece interface lead to more material flow towards workpiece edges resulting inlonger burr. Simulation results of chip morphologies and cutting forces for turning analuminum alloy A2024-T351 have been compared with the experimental ones. Finally, it hasbeen concluded that the newly proposed geometry of the insert not only decreases the burrbut also helpful in lessening the magnitude of tool-workpiece initial impact.