Theoretical and experimental studies of chatter in turning and machining stainless steel workpiece

This paper focuses on predicting regenerative chatter onset conditions in machining stainless steel. To establish a credible regenerative chatter model, the mass and flexibility of the workpiece are considered and modeled for lateral deformations using the Timoshenko beam theory; the motion of the cutting tool is modeled as a mass-spring-damper system. The varying natural frequencies and dynamic stiffness of the tool-workpiece system during the cutting process are simulated to study the influence of tool position and material loss. The Johnson-Cook (JC) material model is firstly used as the cutting force model for AISI 316L in chatter analysis to understand the influence of tool geometry and cutting parameters. The effect of dynamic bending moment caused by the axial component of the cutting force is also considered for the first time. Simulations were conducted to understand the influence of tool geometry and cutting parameters on chatter onset conditions. Experiments were carried out to verify the proposed approach on three types of cutting tools.