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Chip morphologies have been documented, classified and characterized for decades within the metal cutting community. Based on these studies, it is generally appreciated that chip morphologies reflect the underlying cutting process. However, specific details of plastic flow processes that are responsible for chip shape, roughness and morphology have hitherto remained largely unclear. In this work, we show a unique correspondence between mesoscale (10–100 µm) plastic flow modes and resulting in chip morphologies. Using high-speed in situ observations and image analysis, we demonstrate three distinct plastic flow modes—all non-homogeneous and unsteady—that are unlike the usually assumed homogeneous shear plane/zone models for metal cutting. These flow modes have their own unique initiation and evolution criteria, as reflected in chip strains and material flow patterns. The latter are computed …