A new receptance coupling substructure analysis methodology to predict tool tip dynamics

Tool tip frequency response function (FRF) is essential for chatter stability diagram in machining. But new modal tests are required for different tool-holder-spindle assemblies. To avoid these tests, receptance coupling substructure analysis (RCSA) method has been developed. Previous research proved that the full receptance matrix, which contains rotational and moment contributes, influences the RCSA accuracy. By improving the accuracy and efficiency in acquiring the full receptance matrix, this paper presents a new RCSA methodology to predict the tool tip dynamics when a new tool is selected. To identify the contact dynamics between the tool and tool holder, one required receptance matrix is experimentally measured with a reference tool attached on the machine. Comparing to the classical RCSA technique, an enhanced approach is proposed to better estimate the receptance matrix. Only one impact positon is required in the experiment. The enhanced approach introduces two compensation strategies to process the measuring data from impact test. Each compensation strategy can be chosen to improve the estimation accuracy. The measured receptances, together with the finite element models of the reference tool and the new tool, are used to predict the unknown tool tip FRF. Both numerical simulation and practical experiment are conducted to validate the proposed methodology. The results show that the proposed method is preferred when multiple modes should be considered. •A RCSA methodology to predict tool tip dynamics when a new tool is selected.•The methodology integrates the convenience and accuracy in the estimation of the full receptance matrix.•Only one impact position is required in the experiment.•The methodology is preferred when multiple modes should be considered.