An improved stability lobe and turning chatter characteristic investigation.

Highlights • A dynamic model for turning chatter prediction considering modal parameters of tool system and workpiece system, tool angles and modal angles is established. • A method for judging chatter based on a width-distance lobe was presented to improve width-speed lobe for turning chatter prediction. • The verification of turning chatter is carried out by using improved chatter stability prediction combined with surface contour detection. • Mechanism of chatter formation and chatter mark formation are analyzed. • A mathematical model of the chatter angle in view of composite angle of motion velocity and motion displacement is established. Abstract A quick chatter identification method using continuous variable speed programing was proposed to solve radial turning chatter. A width-distance lobe (b - d lobe) was presented to improve width-speed lobe (b - n lobe) for turning chatter prediction. The turning dynamic model for chatter prediction considering modal parameters of tool system and workpiece system, tool angles and modal angles was established. And the model verification was carried out by the combination of improved chatter lobe with surface contour, which showed that the improved chatter stability lobe can well corresponds to the machined surface. On this basis, the mechanism of surface formation of turning chatter were analyzed. In addition, the advantages of the improved b - d lobe were discussed compared with the previous b - n lobe no matter in workload, difficulty, skill requirements and time consumption. And, the method was verified useful by an application example of brake disc processing in automotive industry. Another finding is the chatter direction of the radial turning which is expressed by mathematical models of chatter angles. Graphical abstract Image, graphical abstract [ABSTRACT FROM AUTHOR]