Micro-miniature orthogonal turn-milling chatter analyses based on regenerative theory

Chatter in micro-miniature turn-milling is analyzed using the nonlinear delay differential equations (DDEs) for orthogonal turn-milling. The DDEs are linearized to determine the chatter frequencies. The theoretical analysis agrees well with orthogonal turn-milling experiments. The measured and calibrated frequencies show that the chatter frequency is close to the secondary Hopf bifurcation frequency. Therefore, the secondary Hopf bifurcation reflects the chatter measured in orthogonal turn-milling.