A comprehensive chatter prediction model for face turning operation including tool wear effect

This paper presents a three-dimensional mechanistic frequency domain chatter model for face turning processes, that can account for the effects of tool wear including process damping. New formulations are presented to model the variation in process damping forces along nonlinear tool geometries such as the nose radius. The underlying dynamic force model simulates the variation in the chip cross-sectional area by accounting for the displacements in the axial and radial directions. The model can be used to determine stability boundaries under various cutting conditions and different states of flank wear. Experimental results for different amounts of wear are provided as a validation for the model.