Extending the inverse receptance coupling method for prediction of tool-holder joint dynamics in milling

► A new less costly approach for predicting tool tip FRF. ► Extended inverse RCSA to identify the holder FRFs in arbitrary joint points. ► Experimental determination of the holder FRFs without separating the tool. ► The inclusion of joint parameters effect in the identified holder FRFs. ► No need for identification of joint parameters through tedious fitting methods. Recently, receptance coupling substructure analysis (RCSA) is used for stability prediction of machine tools through its dynamic response determination. A major challenge is the proper modelling of the substructures joints and determination of their parameters. In this paper, a new approach for predicting tool tip FRF is presented. First, inverse RCSA formulation is extended so that the holder FRFs can be identified directly through experimental modal tests. The great advantage of this formulation is its implementation in arbitrary point numbers along joint length. Therefore, in comparison with previous inverse RCSA approaches, a more realistic joint model can be considered. In addition, due to applying the new approach, additional costly modal tests on the gauged tool are not required. This characteristic makes it possible to determine the holder FRFs without separating the tool; especially in situations where the holder end is inaccessible. The inclusion of joint parameters effect in the identified holder FRFs is another main advantage of such approach. Consequently, for identification of joint parameters, there is no need to use common error optimization based on fitting methods. The effect of overhang length is investigated through some analytical study and also experimental validation. Results show that the predicted tool tip FRF is exact in analytical case. Moreover, due to less noise effect, the predictions based on identified FRFs of longer tools are more accurate than the shorter ones (in experimental case).