Dynamic substructuring in metal cutting machine chatter

Paper in proceeding, 2010

In metal cutting, spindle speed optimization for process stability is one example of action that may reduce production time and increase process reliability. For process stability, it is crucial to avoid regenerative vibrations and thereby enable larger cutting depth, with higher material removal rate as benefit. A spindle speed optimization is usually based on the machine tool and cutting tool assembly’s frequency response at the tool-tip. This is normally obtained by dynamic testing of the full assembly. In this paper we use a receptance coupling technique to reduce testing time by synthesizing the frequency response displacement function of the system. The method utilizes test data of the machine tool with an inserted blank tool together with a finite element representation of the real cutting tool. The coupling is made via a state space coupling technique. Comparisons are made with data from full system tests and a stability prediction is demonstrated.