Application of interpolation methods for the determination of position-dependent frequency response functions for the simulation of 5-axis milling processes

Abstract The occurrence of chatter vibrations in 5-axis milling processes is a common problem and can result part failure, surface defects increased wear the cutting tool machine tool. In order to prevent process vibrations, machining be optimized by utilizing geometric physically-based simulation systems. Since modal parameters are dependent on position linear rotary axes, dynamic behavior change along NC path despite constant engagement conditions. model pose-dependent properties at tip, frequency response functions (FRFs) were measured different locations workspace for various poses axis spindle. To take varying compliance within into account simulation, interpolation methods interpolating FRFs or parameter values oscillator-based models (OPV) applied. For validation, resulting analyzed compared data. OPV interpolation, individual oscillation modes interpolated their respective characteristics based oscillator (eigenfrequencies, masses damping values). FRF however, there was no differentiation between modes, wrong interpolation. It therefore provide good results when only small shift eigenfrequencies expected, as case tool, with movements translatory axes.