The requirements for massive high-performance components are constantly increasing. In addition to the reduction of component weight, requirements such as smaller design, more functionality and longer lifetime are increasing. By joining different materials in one component, these contradictory requirements can be met. In the process chain of manufacturing hybrid components, machining as the final step has a decisive influence on the application behavior and service life due to the surface and subsurface properties generated. Thereby thermomechanical loads during machining determine the final subsurface properties and the chip formation mechanisms determine the final surface properties of components. However, for the specific adjustment of required surface and subsurface properties, first of all an understanding of the generation of the addressed properties in the material transition zone is necessary. In the current work, the chip formation and the mechanical loads in the transition zone of hybrid components are presented. Within the scope of orthogonal cutting investigations, the influence of process parameters and tool microgeometry on mechanical loads and chip formation is analyzed. Chip forming has a significant influence on the surface properties of the hybrid component. The chip formation depends on the hardness of the machined material. During machining of hybrid components an abrupt change of the chip shape takes place in the material transition zone. The process variables influence the level in the surface topography of hybrid components. © 2020, The Author(s).