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In-situ strain measurements with high energy synchrotron radiation during orthogonal cutting of AISI1045 were carried out. Thereby it was possible to determine the stress state in the chip formation zone during the cutting process. As such, observations regarding the formation of built-up edges during the cutting process have been made. The formation of a built-up edge on the cutting tool is a common phenomenon during cutting of mild steel and other ductile materials, in particular at low cutting speeds. This may result in increased tool wear and a decrease in the resulting surface quality. By analyzing the chip roots of the in-situ experiments, it was possible to determine the geometry of the built-up edges on tools with a rake angle of = 0° and cutting edge radii of r = 30 μm and r = 60 μm. Using the obtained data a simulation model which represents the built-up edge could be established with two versions of the built-up edge: a solid one as part of the rigid tool and an elastic one in front of the tool. Using FEM cutting simulations with and without built-up edges, it was possible to show the influence of a built-up edge on the chip formation and the stress state in the chip formation zone. With this data, a comparison of the results of the cutting simulations with those of the in-situ experiments was conducted.

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