Turning is the widely machining process used for brake rotor manufacturing while turning cost is a one factors that many has a huge impact on manufacturing cost for second tier manufacturer so increase tool life is always needed developed in second tier manufacturer. This paper would like to investigate effect of microstructure and graphite morphology of gray cast iron which is the most widely materials use in brake rotor on machinability. The tested material was class FC250. The raw test was made of steel scrap, returned material at the ratio of 60 : 40. Controlled inoculation technique was inoculated in ladle compare with inoculated both in ladle and were in melting stream while pouring in horizontal greensand mould. The microstructure measured by optical microscopy and cutting force investigated by dynamometer. The experimental were observed to achieve the result of minimize cost among raw material, turning process cost, insert cost, and meet the product criteria of friction brake performance.