Three-Component Receptance Coupling Substructure Analysis for Tool Point Dynamics Prediction

Abstract

In this paper we present the second generation receptance coupling substructure analysis (RCSA) method, which is used to predict the tool point response for high-speed machining applications. This method divides the spindle-holder-tool assembly into three substructures: the spindle-holder base; the extended holder; and the tool. The tool and extended holder receptances are modeled, while the spindle-holder base subassembly receptances are measured using a "standard" test holder and finite difference calculations. To predict the tool point dynamics, RCSA is used to couple the three substructures. Experimental validation is provided.

On the use of structural dynamics in virtual manufacturing

“…3 allows one to obtain the tool-holder-spindle-machine (THSM) FRF, as reflected at the tool point, individual measurements are required for each assembly [20]. In general, a computer numerically controlled (CNC) machine has several tools and holders, and therefore, measurements on several toolholder combinations would be required.…”

“…The main problem to the implementation of high-speed machining of flexible parts or/and cutting tools is an unstable machining condition, known as chatter [11,15,17,20]. Chatter is caused by regeneration of waviness, or the overcutting of the surface left by one tooth of the vibrating cutter by subsequent teeth [9], and can affect the machined surface of the part or increase considerably the tool wear.…”

Shrink fit tool holder connection stiffness/damping modeling for frequency response prediction in milling

“…The purpose of this paper is to build on the previous work of Schmitz et al [1][2][3][4][5][6][7][8], which describes tool point FRF, or receptance, prediction using the receptance coupling substructure analysis (RCSA) method. In these previous studies, two-and three-component models of the machine-spindle-holder-tool assembly were defined.…”

“…Further, the measured response is often strongly dependent on the tool overhang length. Therefore, a model which is able to predict the tool point response based on minimum input data is the preferred alternative [1][2][3][4][5][6][7][8][9][10][11][12][13].…”

An approach to evaluate the effects of nonlinear traveling joints on dynamic behavior of large machine tools

“…Several papers have reported on modeling the stiffness and damping characteristics of machine joints [15][16][17][18]. Substructure synthesis methods [19] and impedance coupling methods [20] have been developed and used extensively in the dynamic analysis of assembled structures. However, the nonlinear effect of traveling joints was also not considered in these methods.…”