Among other factors, the material removal rate in turning is limited by the occurrence of regenerative chatter. This phenomenon is undesirable, as it leads to poor surface quality, accelerated tool wear, or even tool breakage. Prediction models for regenerative chatter, such as stability lobe diagrams, are rarely used in practice due to their lack of accuracy. The goal of this thesis is to derive, validate, and apply a dynamic analytical model of the tool–workpiece system that can reliably predict the dynamic response during turning and, consequently, the occurrence of regenerative chatter, on the basis of turning parameters (feed rate and cutting edge geometry). The inputs to the proposed model include frequency response functions of both the tool and the workpiece on the selected machine, as well as cutting force coefficients per chip cross-sectional area, characterized in this work for aluminium, steel, and stainless steel. The model output is a stability lobe diagram showing the limiting depth of cut (the maximum depth of cut at which chatter does not occur) as a function of spindle speed. The proposed model is validated through experimental testing.
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