Shahrood University of Technology Journal of Solid and Fluid Mechanics 2251-9475 15 5 2025 11 22 Simulation and analysis of chatter onset in orthogonal cutting process using an energy-based approach Simulation and analysis of chatter onset in orthogonal cutting process using an energy-based approach 331 347 3743 10.22044/jsfm.2025.16071.3965 FA Mohammad Ghorbani Department of Mechanical Engineering, Shahreza Campus, University of Isfahan, Iran Mostafa Sarjoughian Department of Mechanical Engineering, Shahreza Campus, University of Isfahan, Iran Journal Article 2025 04 26 This paper simulates workpiece vibrations in the orthogonal cutting process, from the initial engagement of the tool and workpiece, to conduct an in-depth investigation of chatter onset using an energy-based approach. For this purpose, the orthogonal cutting process of a disk is divided into two distinct stages: the first revolution of the workpiece and the subsequent revolutions. The governing vibration equations for each stage are derived separately. The first-stage equation is solved analytically, while the second-stage equation is solved using the semi-discretization method. Additionally, formulations for calculating the power and energy transmitted by the cutting force and dissipated due to system damping are presented. Through simulations, a comprehensive analysis of the system's vibrational behavior during the initial revolutions of the workpiece is conducted. The findings indicate that the system behavior during the first three revolutions, regardless of cutting width, is determined by the transient response in the first revolution caused by the tool feed. Furthermore, the results show that in the stable condition, the total power is zero; in the critically stable condition, it oscillates with a constant amplitude and a zero average value; and in the unstable condition, it oscillates with an increasing amplitude and a zero average value. This paper simulates workpiece vibrations in the orthogonal cutting process, from the initial engagement of the tool and workpiece, to conduct an in-depth investigation of chatter onset using an energy-based approach. For this purpose, the orthogonal cutting process of a disk is divided into two distinct stages: the first revolution of the workpiece and the subsequent revolutions. The governing vibration equations for each stage are derived separately. The first-stage equation is solved analytically, while the second-stage equation is solved using the semi-discretization method. Additionally, formulations for calculating the power and energy transmitted by the cutting force and dissipated due to system damping are presented. Through simulations, a comprehensive analysis of the system's vibrational behavior during the initial revolutions of the workpiece is conducted. The findings indicate that the system behavior during the first three revolutions, regardless of cutting width, is determined by the transient response in the first revolution caused by the tool feed. Furthermore, the results show that in the stable condition, the total power is zero; in the critically stable condition, it oscillates with a constant amplitude and a zero average value; and in the unstable condition, it oscillates with an increasing amplitude and a zero average value. https://jsfm.shahroodut.ac.ir/article_3743_1cbe3ecd415cb9446e93cdf2c5b8d05d.pdf