The processed surface texture caused by cutting chatter contains an abundance of processing state information. Aiming at chatter issues in the turning of thin-walled cylindrical workpieces, this study adopts a combination of theoretical analysis, numerical simulation and experimental testing to study the formation mechanism of surface pattern under turning chatter. The influence of workpiece dynamics and machining parameters on surface patterns is investigated. First, the finite element method is used to obtain the changing law of the thin-walled shell mode with the cutting position change during a complete pass, and it is concluded that the natural frequency of the workpiece shell mode has a significant decreasing trend. Furthermore, combined with the cutting surface topography model, the formation mechanism of the special vibration pattern is derived and explained theoretically, which is related to the size of the workpiece, the reduction of the natural angular frequency per unit time, and the square of the number of turns. Finally, cutting experiments were conducted to verify the theoretical results. The special vibration pattern on the surface of the thin-walled tube was reproduced using the chatter frequency and workpiece dimensions, and cutting parameters in the turning process. The research is of significance for prediction and control of the surface morphology of thin-walled cylinders in turning operations.
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