Stability lobes for general turning operations with slender tools in the tangential direction

During the turning of large and heavy cases and rings, the tool must be cantilevered over long distances, and chatter due to modes in the tangential direction may occur. This paper proposes a numerical method based on a nonlinear cutting force model, which includes the effects of the cutting parameters to construct precise stability charts for this special machining case. This method has been successfully applied to general cutting geometries in rough and medium longitudinal turning operations, assuming a rigid workpiece and a flexible tool. This study proposes a dynamic model to implement the effects of the tangential mode on chip regeneration in the regenerative plane based on an experimentally obtained dynamic displacement factor. From the simulations and experimental results, the model provides a reliable approach to obtain chatter-free turning conditions.

► Stability prediction of longitudinal turning operations with slender tools. ► Development of a single DOF model to predict chatter from tangential modes. ► The method considers variable cutting coefficients depending on the cutting parameters. ► Dynamic behaviour of different tool setups has been identified. ► The simulations agreed with the experimental results.