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TY - THES AU - Chavan, Prateek Satish TI - Substructuring methods for efficient prediction of spindle-holder-tool assembly dynamics; 1. Auflage VL - 2023,18 PB - RWTH Aachen University VL - Dissertation CY - Aachen M1 - RWTH-2023-05756 SN - 978-3-98555-160-6 T2 - Ergebnisse aus der Produktionstechnik SP - 1 Online-Ressource : Illustrationen, Diagramme PY - 2023 N1 - Druckausgabe: 2023. - Auch veröffentlicht auf dem Publikationsserver der RWTH Aachen University. - Weitere Reihe: Werkzeugmaschinen. - Weitere Reihe: Edition Wissenschaft Apprimus N1 - Dissertation, RWTH Aachen University, 2023 AB - This thesis provides a framework of efficient experimental and analytical substructuring methods for the reliable prediction of spindle-holder-tool assembly dynamics. Specifically, this implies the prediction of the tool tip Frequency Response Functions (FRFs) as well as the tool tip-Spindle Integrated Displacement Sensors (SIDS) transfer functions for a main spindle equipped with contactless displacement sensors. Here, the holder-tool assembly is modelled analytically whereas the spindle substructure is modelled experimentally. The knowledge of the spindle-holder-tool assembly dynamics is indispensable for a variety of applications such as prediction of stability behavior, process forces, tool deflection during cutting as well as virtual surface quality. For achieving high-quality experimental response models, three important aspects are researched. Firstly, strategies for measurement of displacement-to-force compliances are systematically compared and assessed. Secondly, two new methods for the identification of rotational compliances are proposed based on a modal parameter approach and commercially available rotational accelerometers. Thirdly, an experimental method for obtaining the interface flange-SIDS transfer function matrix and corresponding measurement uncertainty is developed and validated. This is required for prediction the tool tip-SIDS transfer function along with propagated un-certainty bounds. A significant challenge in the analytical response modelling of holder-tool assemblies is that certain features like joint parameters cannot practically be modeled a priori and require additional reference measurements for their parametrization. Instead of using FRFs of the tool clamped in the machine spindle, this thesis utilizes the measurement of reference FRFs in an offline, freely constrained state of the tool assembly. A precise feature parameterization is made possible by the developed extended tool model updating approach. Using this approach, a priori unknown parameters like joint stiffness and effective diameter of the fluted segment are reliably parameterized and validated for several different holder-tool assemblies in a completely offline manner. Furthermore, methods for the accurate beam modelling of various holder features such as balancing holes, tapered segment and holder-inserted tool segment were developed, analyzed and systematically validated. Another valuable contribution of this thesis is demonstrating the utility of the predict-ed tool tip and tool tip-SIDS FRFs for estimating process forces and virtual work-piece quality. In this regard, the practical integration of the developed substructuring methods with an existing virtual quality framework is presented and successfully implemented to estimate process forces and workpiece quality for different milling operations and tool assemblies. LB - PUB:(DE-HGF)11 ; PUB:(DE-HGF)3 DO - DOI:10.18154/RWTH-2023-05756 UR - https://publications.rwth-aachen.de/record/959651 ER -