Numerical simulation of interaction of mode-coupling and regenerative chatter in machining

Chatter vibration is a major obstacle in achieving high performance machining. In order to present a realistic model of chatter vibration, in this research, a finite element simulation of orthogonal chip formation combined with a 2D model of machine tool dynamics is developed. The proposed approach has the ability to incorporate various, mostly nonlinear, phenomena affecting chatter occurrence. The dynamic allows the tool to vibrate as a result of chip load variation leading to chatter. The 2DOF model makes it possible to observe the occurrence of model coupling phenomenon, in addition to the regeneration of waviness mechanism. The investigation of mode-coupling and regeneration phenomena in turning demonstrate the interaction between these two major mechanisms of chatter. It is observed that with the inclusion of mode coupling, the process becomes unstable more quickly. The model is verified through comparison with experimental results.