<p>Chip formation plays a vital role in the machining quality and tool wear during successful hole-making process, especially in drilling of aerospace laminated components. For this purpose, the present study aims to offer an enhanced interpretation of the drilling process on Al/Ti laminates by combining finite element method (FEM) with experiments. It contributes to relating the chip formation mechanism with their drilling characteristics. Specifically, according to different drilling stages, in addition to considering the dynamic formation and macroscopic chip flow kinematics, the mechanism of serrated chip forming under different materials are also considered. Simplified 2D and 3D drilling models based on the Johnson-Cook (J-C) constitutive equation combined with energy-based damage evolution law were established. The simulation results showed that the cutting force exhibits periodic fluctuations corresponding to the formation of each serration; the thrust force decreases with increasing cutting speed, while the torque initially increases and then decreases. In addition, it is worth noting that the prediction errors of cutting force, torque and chip morphology are all within 10%, which indicates the validity of the model. This study not only deepens the understanding of the formation mechanisms of chip but also contributes significantly to the prediction of cutting parameters.</p>