An analysis of the chatter behavior for a slender cutting tool in turning in the presence of wear flat onthe tool flank is presented in this research. The mechanism of a self-excited vibration developmentprocess with tool wear effect is studied. The components contributing to the forcing function in theturning vibration dynamics are analyzed in the context of cutting force and contact force. Acomparison of the chatter stability for a fresh cutting tool and a worn cutting tool is provided. Stabilityplots 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 characteristicparameters involved in the vibration system and to identify the analytical stability limits. Thetheoretical result of chatter stability agrees qualitatively with the experimental result concerning thedevelopment of chatter stability model with tool wear effect.
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