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The authors would like to acknowledge the support of the National Natural Science Foundation of China (Grant No. 51375160, 51375161).

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Duncan GS, Schmitz T (2005) An improved RCSA model for tool-point frequency response prediction, in: Proceedings of the 23rd International Modal Analysis Conference, 30 January-3 February 2005, Orlando, FL (on CD)

Schmitz TL, Davies MA, Kennedy MD (2001) Tool-point frequency response prediction for high-speed machining by RCSA. J Manuf Sci Eng 123(4):700–707. https://doi.org/10.1115/1.1392994

Merdol SD, Altintas Y (2004) Multi frequency solution of chatter stability for low immersion milling. J Manuf Sci E-T ASME 126(3):459–466. https://doi.org/10.1115/1.1765139

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Smith S, Winfough W, Halley J (1998) The effect of tool length on stable metal removal rate in high-speed milling. CIRP ANN Manuf Technol 47(1):307–310. https://doi.org/10.1016/S0007-8506(07)62839-X

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Yang Y, Zhang WH, Ma YC, Wan M (2015) Generalized method for the analysis of bending, torsional and axial receptances of tool-holder-spindle assembly. Int J Mach Tools Manuf 99:48–67. https://doi.org/10.1016/j.ijmachtools.2015.08.004

Li ZQ, Wang ZK, Shi XF (2017) Fast prediction of chatter stability lobe diagram for milling process using frequency response function or modal parameters. Int J Adv Manuf Technol 89(9–12):2603–2612. https://doi.org/10.1007/s00170-016-9959-4

Mancisidor I, Urkiola A, Barcena R, Munoa J, Dombovari Z (2014) Receptance coupling for tool point dynamic prediction by fixed boundaries approach. Int J Mach Tools Manuf 78(1):18–29. https://doi.org/10.1016/j.ijmachtools.2013.12.002

Altintas Y, Budak E (1995) Analytical prediction of stability lobes in milling. CIRP ANN Manuf Technol 44(7):357–362. https://doi.org/10.1016/S0007-8506(07)62342-7

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Minis I, Yanushevsky R (1993) A new theoretical approach for the prediction of machine tool chatter in milling. J Eng Ind ASME 115(1):1–8. https://doi.org/10.1115/1.2901633

Budak E, Altintas Y (1998) Analytical prediction of chatter stability in milling—part I: general formulation. J Dyn Syst-T ASME 120(1):22–30. https://doi.org/10.1115/1.2801317

Li, Z., Wang, Z., Shi, X. et al. RCSA-based prediction of chatter stability for milling process with large axial depth of cut. Int J Adv Manuf Technol 96, 833–843 (2018). https://doi.org/10.1007/s00170-018-1615-8

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Insperger T, Stepan G (2004) Updated semi-discretization method for periodic delay-differential equations with discrete delay. Int J Numer Methods Eng 61(1):117–141. https://doi.org/10.1002/nme.1061

Bayly PV, Mann BP, Schmitz TL, Peters DA, Stepan G, Insperger T (2002) Effects of radial immersion and cutting direction on chatter instability in end milling. In: Proceedings of IMECE 2002, ASME, pp 351–363

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Kivanc EB, Budak E (2004) Structural modeling of end mills for form error and stability analysis. Int J Mach Tools Manuf 44(11):1151–1161. https://doi.org/10.1016/j.ijmachtools.2004.04.002

Ding Y, Zhu LM, Zhang XJ, Ding H (2010) A full-discretization method for prediction of milling stability. Int J Mach Tools Manuf 50(5):502–509. https://doi.org/10.1016/j.ijmachtools.2010.01.003

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Large axial depth of cut is often used in rough milling to improve its machining efficiency or in finish peripheral milling to remove the machining mark. Novel strategy and methodology were proposed in the paper to predict the chatter stability for milling process with large axial depth of cut. The actual tool-point is first determined by the axial depth of cut, the machine-spindle-tool assembly is divided into two components, the machine-spindle-shank and the cutting edge, the tip receptance is obtained using the experiment modal analysis (EMA) method, the tip receptance of the cutting edge component is obtained analytically, and the tool-point dynamics of the machine-tool system is achieved using the receptance coupling substructure analysis (RCSA) technology. The stability lobe diagram (SLD) corresponding to certain tool-point position is obtained using the classical zeroth-order approximation (ZOA) approach, and thus, the SLD of milling process with large axial depth of cut is obtained by considering the actual tool-point position corresponding to different axial depth of cut and the effect of tool-point position on the predicted SLD. The proposed method for obtaining SLD of milling process with large axial depth of cut is verified by cutting test result. As a result, it can be used as a guidance for milling process with large axial depth of cut in shop floor application.

Chen HH, Xu F (2003) A dual fitting algorithm for modal parameters identification. Mech Syst Signal Process 17(3):713–721. https://doi.org/10.1006/mssp.2002.1501

Li ZQ, Liu Q (2008) Solution and analysis of chatter stability for end milling in the time-domain. Chin J Aeronaut 21(2):169–178

Budak E, Altintas Y (1998) Analytical prediction of chatter stability in milling—part II: application of the general formulation to common milling systems. J Dyn Syst-T ASME 120(1):31–36. https://doi.org/10.1115/1.2801318

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Li ZQ, Wang ZK, Peng YR, Zhu F, Ming XZ (2016) Prediction of chatter stability for milling process using Runge-Kutta based complete discretization method. Int J Adv Manuf Technol 86(1–4):943–952. https://doi.org/10.1007/s00170-015-8207-7

Shih CY, Tsuei YG, Allemang RJ, Brown DL (1988) A frequency domain global parameter estimation method for multiple reference frequency response measurements. Mech Syst Signal Process 2(4):349–365. https://doi.org/10.1016/0888-3270(88)90059-3

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Mann BP, Bayly PV, Davies MA, Halley JE (2004) Limit cycles, bifurcations, and accuracy of the milling process. J Sound Vib 277(1–2):31–48. https://doi.org/10.1016/j.jsv.2003.08.040

Schmitz T, Davies M, Medicus K, Synder J (2001) Improving high-speed machining material removal rates by rapid dynamic analysis. CIRP ANN Manuf Technol 50(1):263–268. https://doi.org/10.1016/S0007-8506(07)62119-2

Park SS, Altintas Y, Movahhedy M (2003) Receptance coupling for end mills. Int J Mach Tools Manuf 43(9):889–896. https://doi.org/10.1016/S0890-6955(03)00088-9