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The aim of this article is the characterization of the conditions in the chip forming area during machining of normalized tempering steel C45E (AISI 1045) at high cutting speeds. Especially the effects of the machining process on the microstructure are described. Infeed turning is the chosen production process. The chips and partially formed chips are taken from a real cutting process. The chip formation clearly shows a 3D character. The shear bands can start and end in the chip or mismatches can be seen. The geometrical parameters vary a lot over the chip width. Investigations using a transmission electron microscope show initially an inhomogeneous dislocation structure in the material as a consequence of the deformation caused by the cutting process. Thereafter, the shear bands are formed by the generation of subgrains and microbands, starting from a dislocation cell structure. The material between the bands is only slightly deformed. Martensitic phase transformations were detected in the shear bands.

3D and microstructural analysis of the chip formation during high speed cutting of C45E (AISI 1045)