Chatter vibration is a major obstacle in achieveing increased machining performance. In this research, a finite element model of chip formation in a 2D milling process is used to predict the occurrence of chatter vibrations, and to investigate the effects of various machining parameters on this phenomenon. The dynamic properties of the machine tool at the tool tip are obtained based on experimental modal analysis, and are used in the model as the cutter dynamics. The model allows for the natural development of vibration as the result of the chip-tool engagement, and accounts for various phenomena that occur at the chip-tool interface ultimately leading to stable or unstable cutting. The model was used to demonstrate the effects of the machining parameters, such as the axial depth of cut, radial immersion, and feed rate, on the occurrence of chatter. Additionally, the phenomenon of jumping out of the cut region could be observed in this model and its effect on the chatter process is demonstrated. The numerical model is verified based on comparisons with experimental results.
This is a preview of subscription content, access via your institution.
Buy single article
Instant access to the full article PDF.
Tax calculation will be finalised during checkout.
Tobias S, Fishwick W (1958) The chatter of lathe tools under orthogonal cutting conditions. Trans ASME 80(2):1079–1088
Tlusty J, Polacek M (1963) The stability of machine tools against self-excited vibrations in machining. Int Res Prod Eng 1(1):465–474
Merritt HE (1965) Theory of self-excited machine-tool chatter: contribution to machine-tool chatter research. J Manuf Sci Eng 87(4):447–454
Sridhar R, Hohn R, Long G (1968) A general formulation of the milling process equation: contribution to machine tool chatter research 5. J Manuf Sci Eng 90(2):317–324
Hanna N, Tobias S (1974) A theory of nonlinear regenerative chatter. J Manuf Sci Eng 96(1):247–255
Wang Y, Wang T, Yu Z et al (2015) Chatter prediction for variable pitch and variable helix milling. Shock Vib. https://doi.org/10.1155/2015/419172
Moradi H, Bakhtiari-Nejad F, Movahhedy MR et al (2010) Nonlinear behaviour of the regenerative chatter in turning process with a worn tool: forced oscillation and stability analysis. Mech Mach Theory 45(8):1050–1066
Tlusty J, Zaton W, Ismail F (1983) Stability lobes in milling. CIRP Ann Manuf Technol 32(1):309–313
Mahnama M, Movahhedy M (2010) Prediction of machining chatter based on FEM simulation of chip formation under dynamic conditions. Int J Mach Tools Manuf 50(7):611–620
Mahnama M, Movahhedy MR (2012) Application of FEM simulation of chip formation to stability analysis in orthogonal cutting process. J Manuf Process 14(3):188–194
Moufki A, Devillez A, Segreti M et al (2006) A semi-analytical model of non-linear vibrations in orthogonal cutting and experimental validation. Int J Mach Tools Manuf 46(3–4):436–449
Hajmohammadi MS, Movahhedy MR, Moradi H (2014) Investigation of thermal effects on machining chatter based on FEM simulation of chip formation. CIRP J Manuf Sci Technol 7(1):1–10
Jafarzadeh E, Movahhedy MR (2017) Numerical simulation of interaction of mode-coupling and regenerative chatter in machining. J Manuf Process 27:252–260
Tlusty J, Andrews G (1983) A critical review of sensors for unmanned machining. CIRP Ann Manuf Technol 32(2):563–572
Association A (2000) Aluminum standards and data. Aluminum Association, Arlington
Brar N, Joshi V, Harris B (2009) Constitutive model constants for Al7075-T651 and Al7075-T6. Proc Am Phys Soc Top Group Shock Compres Condens Matter 1195(1):945–948
Bolar G, Joshi S (2014) Three dimensional finite element modeling and simulation of curvilinear thin-wall machining of aluminum 7075-T6 alloy. Processing and fabrication of advanced materials, World Scientific Publishing, Singapore
Tlusty J (2000) Manufacturing processes and equipment. Prentice Hall, Englewood
Insperger T, Stépán G (2004) Updated semi-discretization method for periodic delay-differential equations with discrete delay. Int J Numer Methods Eng 6(1):117–141
About this article
Cite this article
Jafarzadeh, E., Movahhedy, M.R., Khodaygan, S. et al. Prediction of machining chatter in milling based on dynamic FEM simulations of chip formation. Adv. Manuf. 6, 334–344 (2018). https://doi.org/10.1007/s40436-018-0228-7
- Machining chatter
- Finite element model (FEM) simulation
- Feed rate