Modares Mechanical Engineering

Modares Mechanical Engineering

Simulation of Regenerative Chatter Incorporating Velocity- and Acceleration-Dependent Terms in Process Damping Using ADAMS Software

Document Type : Original Article

Authors
Mohammad Ghorbani
Sayyed Hadi Moallem
Department of Mechanical Engineering, Shahreza Campus, University of Isfahan, Iran
10.48311/mme.2025.116947.82865
Abstract
In this paper, regenerative chatter vibrations in orthogonal cutting process are simulated using MSC ADAMS software for the first time. To this end, the governing differential equation of the system's vibrations, caused by wave regeneration mechanism in the presence of process damping and by incorporating velocity- and acceleration-dependent terms, is first derived. The excitation force terms in this equation are then classified into three categories: the excitation force due to static chip thickness, the self-excited force resulting from the difference between the current and previous waves formed on the workpiece (expressed as a delay term), and the frictional force due to process damping, which is a function of the vibration velocity, acceleration, and spindle speed. Subsequently, by developing a vibrational model of the process in ADAMS software, and through an innovative approach using the software’s internal functions, all components of the excitation force, including the static, delayed self-excited, and process damping frictional forces, are applied as external forces to the system. Through simulations, time responses of the system's vibrations are extracted with and without the effect of process damping, across stable, critically-stable, and unstable conditions. Comparison of the simulation results with those obtained from numerical solutions of the equations using semi-discretization method shows excellent agreement. In addition, the behavior of the system predicted by the proposed model is validated through comparison with experimental data reported in previous studies. The developed model, while easy to implement, offers extensibility for simulating more complex chatter scenarios in machining processes
Keywords
Simulation, Regenerative Chatter, Process Damping, MSC ADAMS

Subjects

[1] Y. Caixu, G. Haining, L. Xianli, Y. L. Steven, and W. Lihui, "A review of chatter vibration research in milling," Chinese Journal of Aeronautics, vol. 32, no. 2, pp. 215-242, 2019. doi:10.1016/j.cja.2018.11.007
[2] Y. Altintas, G. Stepan, E. Budak, T. Schmitz, and Z. M. Kilic, "Chatter stability of machining operations," Journal of Manufacturing Science and Engineering, vol. 142, no. 11, p. 110801, 2020. doi:10.1115/1.4047391
[3] M. Mahnama and M. Movahhedy, "Application of FEM simulation of chip formation to stability analysis in orthogonal cutting process," Journal of manufacturing processes, vol. 14, no. 3, pp. 188-194, 2012. doi:10.1016/j.jmapro.2011.12.007
[4] A. Moufki, A. Devillez, M. Segreti, and D. Dudzinski, "A semi-analytical model of non-linear vibrations in orthogonal cutting and experimental validation," International Journal of Machine Tools and Manufacture, vol. 46, no. 3-4, pp. 436-449, 2006. doi:10.1016/j.ijmachtools.2005.04.017
[5] Y. Altintas, M. Eynian, and H. Onozuka, "Identification of dynamic cutting force coefficients and chatter stability with process damping," CIRP annals, vol. 57, no. 1, pp. 371-374, 2008. doi:10.1016/j.cirp.2008.03.048
[6] C. Cao, X.-M. Zhang, T. Huang, and H. Ding, "An improved semi-analytical approach for modeling of process damping in orthogonal cutting considering cutting edge radius," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 234, no. 3, pp. 641-653, 2020. doi:10.1177/0954405419863605
[7] Y. Altintas, Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge university press, 2012. doi:10.1115/1.1399383
[8] Y. Altintas and E. Budak, "Analytical prediction of stability lobes in milling," CIRP annals, vol. 44, no. 1, pp. 357-362, 1995. doi:10.1016/S0007-8506(07)62342-7
[9] S. Merdol and Y. Altintas, "Multi frequency solution of chatter stability for low immersion milling," Journal of Manufacturing Science and Engineering, vol. 126, no. 3, pp. 459-466, 2004. doi:10.1115/1.1765139
[10] X. Dong, X. Shen, and Z. Fu, "Stability analysis in turning with variable spindle speed based on the reconstructed semi-discretization method," The International Journal of Advanced Manufacturing Technology, vol. 117, no. 11, pp. 3393-3403, 2021. doi:10.1007/s00170-021-07869-8
[11] Y. Dai, H. Li, and B. Hao, "An improved full-discretization method for chatter stability prediction," The International Journal of Advanced Manufacturing Technology, vol. 96, no. 9-12, pp. 3503-3510, 2018. doi:10.1007/s00170-018-1767-6
[12] D. Zhan, S. Jiang, S. Li, and Y. Sun, "A hybrid multi-step method based on 1/3 and 3/8 Simpson formulas for milling stability prediction," The International Journal of Advanced Manufacturing Technology, vol. 120, no. 1, pp. 265-277, 2022. doi:10.1007/s00170-022-08705-3
 
[13] W. Baklouti, C. Mrad, and R. Nasri, "Numerical study of the chatter phenomenon in orthogonal turning," The International Journal of Advanced Manufacturing Technology, vol. 99, no. 1-4, pp. 755-764, 2018. doi:10.1007/s00170-018-2528-2
[14] X. Zhang, L. Wan, and X. Ran, "Research progress on the chatter stability in machining systems," The International Journal of Advanced Manufacturing Technology, vol. 131, no. 1, pp. 29-62, 2024. doi:10.1007/s00170-024-13050-8
[15] M. Sadeghifar, R. Sedaghati, W. Jomaa, and V. Songmene, "A comprehensive review of finite element modeling of orthogonal machining process: chip formation and surface integrity predictions," The International Journal of Advanced Manufacturing Technology, vol. 96, no. 9-12, pp. 3747-3791, 2018. doi:10.1007/s00170-018-1759-6
Modares Mechanical Engineering
Volume 26, Issue 1
January 2026
Pages 15-25