There is a lot of discussion and interest in the “Industry 4.0 project”. But before we start teaching a computer for creating AI, the adequate mathematics of the process must be systematic developed and known. This paper presents every phenomenon from the dressed micro geometry of the spherical wheel space, with average edge contour, average undeformed chip thickness and distance from each other. These dynamic cutting edges create friction, ploughing with a frontal bulge and a segmented chip. To advance the field of modelling chip formation it is necessary to find the relevant friction and contact conditions with corresponding process mechanics. The knowledge of the existing stress and strain-rate situation delivers the metal deformation in the plastic zone. The plastic deformation is the only parameter that will not disappear after completing the operation. Therefore, this will be the base to compare the developed theoretical material deformation with the experimental results during the grinding process.