The evolution of chip morphology, chip formation, and surface topography (Ra, Rz) with cutting parameters has become an increasingly important way to achieve higher manufacturing efficiency and better surface topography. In this investigation, the relationships of chip morphology, chip formation, and surface topography with respect to cutting parameters are developed in dry milling of cast aluminum alloys with a PCD inserter. The feed rate affects the surface roughness, although no unanimous trend is observed between cutting parameters and surface topography. Surface crack propagation directly affects the saw-tooth chip morphology and the surface topography. The chip morphology is transformed from saw-tooth to continuous type at a chip deformation ratio of 3; chip deformation ratios of 2.5, 1.875, and 1.25 achieve cutting velocities of 32.71, 35.98, and 39.25 m/s, respectively, in which a continuous chip is formed by surface crack propagation and the predominant effect of thermal softening and surface topography is significantly improved.

具有切削参数的切屑形态，切屑形成和表面形貌（Ra，Rz）的演变已成为实现更高的制造效率和更好的表面形貌的越来越重要的方法。在这项研究中，在使用PCD插入器干铣铸铝合金的过程中，开发了切屑形态，切屑形成和表面形貌与切削参数之间的关系。进给速度会影响表面粗糙度，尽管在切削参数和表面形貌之间没有观察到一致的趋势。表面裂纹的扩展直接影响锯齿形切屑的形态和表面形貌。切屑变形比为3时，切屑形态从锯齿形转变为连续形；2.5、1.875和1.25的切屑变形比可实现32.71、35的切削速度。