Abstract: The prediction of chatter vibration is influenced by many known complex phenomena and is uncertain. We present a new effect that can significantly change the stability properties of cutting processes. It is shown that the microscopic environment of chip formation can have a large effect on its macroscopic properties. In this work, a combined model of the surface regeneration effect and chip formation is used to predict the stability of turning processes. In a chip segmentation sub-model, the primary shear zone is described with a corresponding material model along layers together with the thermodynamic behavior. The surface regeneration is modeled by the timedelayed differential equation. Numerical simulations show that the time scale of a chip segmentation model is significantly smaller than the time scale of the turning process; therefore, averaging methods can be used. Chip segmentation can decrease the average shear force leading to decreased cutting coefficients because of the non-linear effects. A proper linearization of the equation of motion leads to an improved description of the cutting coefficients. It is shown that chip segmentation may significantly increase the stable domains in the stability charts; furthermore, by selecting proper parameters, unbounded stability domains can be reached.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-018-0229-6.pdf

Key words: Chip formation, Chatter, Turning delay