Machining stability in turning operation when cutting with a progressively worn tool insert

Our investigation is aimed at understanding the influence of the interactions between chatter instability and tool-wear/tool-life in turning operations. An integrated experimental and analytical study has been conducted to examine changes in tool-wear with chatter instability for different cutting conditions and progressively worn cutting tools. The major tool-wear/tool-life parameters for typical grooved tools and the corresponding cutting forces in three directions are measured at varying time intervals. The variations in the wear parameters and the cutting forces are compared with the changes in stability charts of the turning operation. Explicit analytical expressions are derived for predicting the onset of chatter instability and tool-wear.