Simulation and analysis of chatter onset in orthogonal cutting process using an energy-based approach

Authors

Department of Mechanical Engineering, Shahreza Campus, University of Isfahan, Iran

10.22044/jsfm.2025.16071.3965

Abstract

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.

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References

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Journal of Solid and Fluid Mechanics
Volume 15, Issue 5
November and December 2025
Pages 331-347

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