Identification of Tool Tip Frequency Response Function Through Surface Location Error

In machining, tool vibrations are one of the main causes of process inaccuracies and poor finishing. To tackle these phenomena, the identification of the tool tip frequency response function (FRF) is essential, since it allows to determine the most suitable cutting conditions for an accurate and stable cut. Nonetheless, the identification of the tool tip FRF is usually achieved through experimental modal methods whose set up and testing phases require specific expertise as well as sensors and devices to be mounted on the machine tool. This paper investigates a methodology to identify tool tip FRF starting from the surface location error (SLE) without the need of additional equipment for the machine tool. The method exploits on-machine sensors (i.e., measuring probe), and it identifies tool tip FRF using a frequency domain cutting force model and the SLEs measured in different cutting tests. The method was experimentally tested to verify its effectiveness and limitations.