A brazed chip breaker capable of controlling the chip curling and flow is proposed on the rake face of a polycrystalline diamond (PCD) tool to obtain ideal chip shape of aluminum alloy materials. Two new position parameters, the breaker-point distance and the rotation angle of chip breaker, are proposed for positioning the chip breaker on the rake face of PCD turning tool. Influences of two position parameters of the chip breaker on the chip curling and chip flow direction are studied through finite element simulations and cutting experiments. The appropriate breaker-point distance can improve the up-curling and back-flow of the chip, and control the chips flow to the tool flank face to form a C-shaped chip. After setting the appropriate breaker-point distance, increasing the rotation angle of chip breaker can promote the trend of side-curling and side-flow of the chip, which is beneficial to the formation of short helical chip. Based on the chip-breaking criterion and the geometric relationship between the chip breaker and tool rake face, the equations of two position parameters of chip breaker are established, and effective chip breaking can be achieved within the reasonable range of chip breaker position parameters calculated by the established equations. The proposed chip breaker which position parameters are convenient to measure and install can be brazed on turning and drilling tools to obtain needed chip shape of aluminum alloy materials. • Proposed two position parameters of chip breaker for PCD turning tools. • Derived a set of equations to determine the effective range of the two position parameters. • Analyzed the influence of the position parameters on the chip curl, chip flow direction and chip shape.