Brian,
I like the way you made the lathe dog. Great observation about the lack of chatter when using HSS vs. carbide (insert?) when machining the thin long taper. There are a lot of factors involved so hard to know the root cause but I like the true slicing action of HSS vs. plowing action of carbide inserts. On slim parts the carbide insert tends to plow in (and out) and flex the part which start a standing wave harmonic motion causing chatter. To make matters worst is the varying diameter along the length changes the parameters so you probably can't find an ideal combination of speed, feed, DOC and lubrication. The sharply hone HSS or cobalt HSS is your best bet.
Thanks for sharing,
Paul

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