Prediction of the Frequency Response Function of a Tool Holder-Tool Assembly Based on Receptance Coupling Method

X. J. Xuan, Z. H. Haung, K. D. Wu, J. P. Hung


Regenerative chatter has a fatal influence on machine performance in high-speed milling process. Basically, machine condition without chattering can be selected from the stability lobes diagram, which is estimated from the tool point frequency response function (FRF). However, measurements of the tool point FRF would be a complicated and time-consuming task with less efficiency. Therefore prediction of the tool point FRF is of importance for further calculation of the machining stability. This study employed the receptance coupling analysis method to predict the FRF of a tool holder-tool module, which is normally composed of substructures, tool holder and cutter with different length. In this study, the angular components of FRFs of the substructures required for coupling operation were predicted by finite element analysis, apart from the translational components measured by vibration experiments. Using this method, the effects of the overhang length of the cutter on the dynamic characteristics have been proven and successfully verified by the experimental measurements. The proposed method can be an effective way to accurately predict the dynamic behavior of the spindle tool system with different tool holder-tool modules.


frequency response function; receptance coupling analysis method; tool holder-tool module

Full Text:



J. Tlusty, M. Polacek, “The Stability of Machine Tools against Self Excited Vibrations in Machining”, in: International Research in Production Engineering, pp. 465-474, ASME, 1963

J. Tlusty, “Dynamics of high-speed milling”, Journal of Engineering for Industry, Vol. 108, No. 2, pp. 59-67, 1986

F. Koenisberger, J. Tlusty, Machine Tool Structures—Vol. I: Stability Against Chatter, Pergamon, Englewood Cliffs, 1967

I. Minis, R. Yanushevsky, A. Tembo, R. Hocken, “Analysis of linear and nonlinear chatter in milling”, CIRP Annals-Manufacturing Technology, Vol. 39, No. 1, pp. 459-462, 1990

T. L. Schmitz, R. R. Donalson, “Predicting high-speed machining dynamics by substructure analysis”, CIRP Annals-Manufacturing Technology, Vol. 49, No.1, pp. 303-308, 2000

T. Schmitz, M. Davies, M. Kennedy, “Tool point frequency response prediction for high-speed machining by RCSA”, Journal of Manufacturing Science and Engineering, Vol. 123, No. 4, pp. 700-707, 2001

T. L. Schmitz, T. J. Burns, “Receptance coupling for high-speed machining dynamics prediction”, 21st Conference & Exposition on Structural Dynamics, Kissimmee, FL, USA, February 3-6, 2003

O. Ozsahin, Y. Altintas, “Prediction of frequency response function (FRF) of asymmetric tools from the analytical coupling of spindle and beam models of holder and tool”, International Journal of Machine Tools and Manufacture, Vol. 92, pp. 31-40, 2015

A. Erturk, H. N. Ozguven, E. Budak, “Analytical modeling of spindle–tool dynamics on machine tools using Timoshenko beam model and receptance coupling for the prediction of tool point FRF”, International Journal of Machine Tools and Manufacture, Vol. 46. No. 15, pp. 1901-1912, 2006

O. Ozsahin, A. Erturk, H. N. Ozguven, E. Budak, “A closed-form approach for identification of dynamical contact parameters in spindle–holder–tool assemblies”, International Journal of Machine Tools and Manufacture, Vol. 49, No. 1, pp. 25-35, 2009

U. V. Kumar, T. L Schmitz, “Spindle dynamics identification for receptance coupling substructure analysis”, Precision Engineering, Vol. 32, No. 3, pp. 435-443, 2012

T. L. Schmitz, G. S. Duncan, “Three-component receptance coupling substructure analysis for tool point dynamics prediction”, Journal of Manufacturing Science and Engineering, Vol. 127, No. 4, pp. 781-790, 2005

P. Albertelli, M. Goletti, M. A. Monno, “A new receptance coupling substructure analysis methodology to improve chatter free cutting conditions prediction”, International Journal of Machine Tools and Manufacture, Vol. 72, pp. 16-24, 2013

T. L. Schmitz, M. A. Davies, K. Medicus, J. Snyder, “Improving high-speed machining material removal rates by rapid dynamic analysis”, CIRP Annals-Manufacturing Technology, Vo. 50, No. 1, pp. 263-268, 2001

S. S. Park, Y. Altintas, M. Movahhedy, “Receptance coupling for end mills”, International Journal of Machine Tools and Manufacture, Vol. 43, No.9. pp. 889-896, 2003

A. Erturk, H. N. Ozguven, E. Budak, “Effect analysis of bearing and interface dynamics on tool point FRF for chatter stability in machine tools by using a new analytical model for spindle–tool assemblies”, International Journal of Machine Tools and Manufacture, Vol. 47, No. 1, pp. 23-32, 2007

E. Budak, A. Erturk, H. N. Ozguven, “A modeling approach for analysis and improvement of spindle-holder-tool assembly dynamics”, CIRP Annals-Manufacturing Technology, Vol. 55, No. 1, pp. 369-372, 2006

eISSN: 1792-8036     pISSN: 2241-4487