Abstract: With the rapid development of modern manufacturing towards high precision and high efficiency, effective control of chip morphology has become a key factor in improving processing quality and safety. Chip morphology not only reflects the processing state but also has a significant impact on processing accuracy, tool life and production safety. Firstly, based on the material deformation mechanism, the formation mechanism of typical chips such as continuous ribbon, serrated and fragmented chips is revealed. On this basis, the prediction methods of chip morphology are summarized, and the advantages and limitations of analytical models, finite element simulation and machine learning are compared and analyzed, providing a theoretical basis for the active regulation of chip morphology. Secondly, the control methods of chip morphology are discussed from aspects such as the regulation of cutting parameters, the optimization of tool structure and auxiliary processing technology, and the mechanism of action, advantages and applicable materials of auxiliary processing technology are summarized. Finally, the new applications of chips in fields such as solid-state recycling of metals and the preparation of functional materials are summarized, and the development direction of intelligent real-time control and green sustainable manufacturing is proposed.