Three Component Model with New Continuous Dynamic Coupling Method for Tool-Holder-Spindle Structure

In machine dynamics, the tool point frequency response functions (FRFs) are employed to predict the stable machining conditions. A combined analytical-experimental substructuring procedure is proposed to determine the tool point FRFs usable for different holder-tool configurations. Contact interface of holder-spindle and tool-holder is modeled using translational and rotational springs and dampers spread in the length of contact surface. These joint parameters are defined using finite element method. This enables the analyst to introduce the contact stiffness and damping in more detail taking into account variations of normal pressure in the tool-holder and holder-spindle joints. The dynamic analysis of the holder is done using Timoshenko beam theory by chebyshev method. The tool dynamics is modeled by Euler-Bernoulli beam theory using the method of equivalent diameter. For the purpose of shifting the tool stability lobes to a higher level, tool damping parameter is modified by internal frictional damper and the effect is analyzed by analytical methods and experimental study. New method for continuous dynamic coupling is presented. The method employs the measured spindle-machine FRFs and analytical models of the tool and holder to predict the tool tip FRFs. An experimental case study is provided to demonstrate the applicability of the proposed method.