A discrete-element approach to model vibro-impact damping in boring bars

Vibro-impact dampers effectively suppress cutting tool vibrations by exploiting the momentum transfer and energy dissipation occurring during impacts between the oscillating system and the free particle(s). The ability to model the cutting tool’s interaction with the particles is crucial in effective design of such dampers. This study explores the capability of Discrete Element Method (DEM), a numerical approach well-suited for modelling discontinuous particle interactions, in simulating the vibro-impacts. An impact-damped boring bar is modeled as a single-degree-of-freedom system with a spherical free mass using the lumped-parameter analytical model, and further simulated using DEM. The study examines different configurations that include a reference case without a damper, as well as elastic and inelastic impact scenarios. DEM results show good agreement with the lumped-parameter model, validating its use for such systems. This approach also demonstrates the potential for future modelling of multi-particle damping configurations, which are analytically intractable, opening new possibilities for advanced vibration control in machining applications.