Abstract
An analysis of the chatter behavior for a slender cutting tool in turning in the presence of wear flat on the tool flank is presented in this research. The mechanism of a self-excited vibration development process with tool wear effect is studied. The components contributing to the forcing function in the turning vibration dynamics are analyzed in the context of cutting force and contact force. A comparison of the chatter stability for a fresh cutting tool and a worn cutting tool is provided. Stability plots are presented to relate width of cut to cutting velocity in the determination of chatter stability. Machining experiments at various conditions were conducted to identify the characteristic parameters involved in the vibration system and to identify the analytical stability limits. The theoretical result of chatter stability agrees qualitatively with the experimental result concerning the development of chatter stability model with tool wear effect.
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