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Dynamic modeling of spindle-tool assemblies in machining centers

Ertürk, Alper
Regenerative chatter is a well-known machining problem that results in unstable cutting process, poor surface quality, reduced material removal rate and damage on the machine tool itself. Stability lobe diagrams supply stable depth of cut ا spindle speed combinations and they can be used to avoid chatter. The main requirement for generating the stability lobe diagrams is the system dynamics information at the tool tip in the form of point frequency response function (FRF). In this work, an analytical model that uses structural coupling and modification methods for modeling the dynamics of spindle-holder-tool assemblies in order to obtain the tool point FRF is presented. The resulting FRF obtained by the model can be used in the existing analytical and numerical models for constructing the stability lobe diagrams. Timoshenko beam theory is used in the model for improved accuracy and the results are compared with those of Euler-Bernoulli beam theory. The importance of using Timoshenko beam theory in the model is pointed out, and the circumstances, under which the theory being used in the model becomes more important, are explained. The model is verified by comparing the results obtained by the model with those of a reliable finite element software for a case study. The computational superiority in using the model developed against the finite element software is also demonstrated. Then, the model is used for studying the effects of bearing and contact dynamics at the spindle-holder and holder-tool interfaces on the tool point FRF. Based on the results of the effect analysis, a new approach is suggested for the identification of bearing and interface parameters from experimental measurements, which is demonstrated on a spindle-holder-tool assembly. The model is also employed for studying the effects of design and operational parameters on the tool point FRF, from the