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Receptance coupling substructure analysis

The receptance coupling substructure analysis (RCSA) approach analytically predicts the tool-holder-spindle-machine assembly frequency response by joining models and measurements of the individual components through appropriate connection parameters. A primary impediment to the full implementation of the large body of academic research in high-speed machining, particularly  chatter (or unstable machining) models, at the production floor is the necessity of measuring each tool-holder-spindle-machine frequency response, typically by impact testing. The chatter models, which can be used to select cutting conditions for both dramatic increases in achievable material removal rates and improved part accuracy, all require knowledge of the tool point frequency response. Due to a lack of engineering support and limited knowledge of dynamic testing procedures, the frequency response measurements may not be completed and the well-established stability-improvement technology (i.e., stability maps, which separate stable and unstable cutting zones graphically as a function of chip width and spindle speed) afforded by high-speed machining is not applied.  The result is reduced process efficiency and part quality and, therefore, increased cost. Using RCSA, the tool point response can be predicted and the obstacle imposed by the necessity for impact testing is removed.