Multi-point coupling for tool point receptance prediction

Schmitz, Tony L.; Honeycutt, Andrew; Gomez, Michael; Stokes, M. J.; Betters, Emma

doi:10.1016/j.jmapro.2019.03.043

Cited by 24 publications

(11 citation statements)

References 96 publications

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“…al [16] or the multipoint RSCA joint model by Schmitz et. al [21] do not show a sensitivity to overhang length. These models provide a more realistic representation.…”

Section: Experimental Implementation and Validationmentioning

confidence: 83%

“…Literature provides several approaches for identifying joint parameters. Some of them are: manual or visual tuning of parameters [13,21], parameter variation [1] and curve fitting or non-linear optimization [9,15]. The objective function for these approaches has been to reduce the difference between the predicted and measured amplitudes within a frequency range.…”

Section: Joint Parameter Identificationmentioning

confidence: 99%

“…This allows for taking into consideration the variation of normal pressure and stiffness along the clamped length as well as surface roughness. Schmitz et al also presented a realistic model of the joint by including multiple connections between the holder and the part of the tool within the holder [20,21]. [16] proposed an approach to identify directly the holdertool joint FRFs at multiple points along the length of the holder using inverse RCSA.…”

Section: Introductionmentioning

confidence: 99%

“…Irrespective of the method employed for modelling the joint, the parameters of the joint model are obtained in majority of approaches by comparing the predicted tool tip FRF with an experimentally obtained tool tip FRF of the tool clamped in a machine spindle [1,6,13,15,21]. Subsequently, the error between prediction and measurement is minimized by varying the joint parameters (usually translational, rotational stiffness and equivalent viscous damping factors).…”

Section: Introductionmentioning

confidence: 99%

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Efficient joint identification and fluted segment modelling of shrink-fit tool assemblies by updating extended tool models

Brecher

Chavan

Fey

2020

Prod. Eng. Res. Devel.

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In milling, the dynamic behavior of the tool center point is crucial for estimating surface quality of the workpiece as well as the process stability behavior. Experimental-analytical receptance coupling can be used for predicting the tool tip dynamics but requires accurate analytical modelling of the holder-tool assembly. This includes the reliable identification of the holder-tool joint properties as well as the correct modelling of the fluted segment of end mills. However, the modelling effort associated with accurately representing the dynamic behavior of the fluted segment is significant. In addition, the joint identification requires a reference tool tip frequency response function of the tool assembly clamped in the machine spindle. This is inefficient and can also lead to incorrect estimation of joint properties. This paper provides an efficient method for joint identification and fluted section modelling using an offline, free–free excitation approach. The objective of this paper is to enable a direct comparison of the dynamic behavior of the freely constrained analytical tool assembly model with that of the real freely constrained tool assembly. The comparison of displacement to force frequency response at certain points on the tool assembly allows for the identification of tool model parameters such as the joint properties and effective diameter of the fluted segment. The comparability is realized by extending the analytical holder-tool beam model to include the receptance model of the standard spindle-holder interface. In this study, as an example, a thermal shrink-fit holder-tool beam model is extended to include an HSK-A63 interface. Subsequently, frequency response functions at two points on the real freely constrained tool assembly are measured in order to identify the joint stiffness and effective diameter of the fluted segment using the corresponding proposed formulations. The updated holder-tool model is then coupled with a 4-axis milling machine and validated. Despite the reduced modelling effort, a good prediction accuracy could be achieved for different holder-tool combinations.

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“…al [16] or the multipoint RSCA joint model by Schmitz et. al [21] do not show a sensitivity to overhang length. These models provide a more realistic representation.…”

Section: Experimental Implementation and Validationmentioning

confidence: 83%

Section: Joint Parameter Identificationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Efficient joint identification and fluted segment modelling of shrink-fit tool assemblies by updating extended tool models

Brecher

Chavan

Fey

2020

Prod. Eng. Res. Devel.

View full text Add to dashboard Cite

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“…To improve the prediction accuracy, Tunc 25 proposed to combine the RCSA method with the stereolithographic (STL) slicing algorithm, and use the approximation method of its 3D model to accurately calculate the cross-sectional properties of the tool such as area and area moment of inertia. Schmitz et al 26 extended the RCSA method from a single-point contact model to a multi-point contact model, expanding the application scope of the RCSA method.…”

Section: Introductionmentioning

confidence: 99%

Research on the stability analysis of milling of thin-walled parts based on the dynamic characteristics

Liu

Zhao

Cui

et al. 2022

The Journal of Strain Analysis for Engineering Design

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Chatter in thin-walled parts is easy to occur in the process of machining, so the analysis of the stability of thin-walled parts has always been a research hotspot. In this paper, considering the influence of cutter eccentricity on milling force first, the coefficients of milling force were able to be identified by combining the milling force model with genetic algorithm. The results show that this method can obtain the milling force coefficients only by one experiment, and the accuracy is higher. Then the tool point Frequency Response Function (FRF) for a given combination can be calculated by using the Receptance coupling substructure analysis (RCSA) method that uses Timoshenko beam theory. Finally, the milling system can be divided into three types by aspect ratio. That is, when aspect ratio is less than 0.03, the system is considered to be a rigid tool-flexible workpiece system, but aspect ratio is between 0.03 and 0.2, the system is considered to be a flexible tool-flexible system, then aspect ratio is greater than 0.2, the system is considered to be a flexible cutter-rigid workpiece system.

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