In precision boring processing, accurate prediction of the radial throw of a boring tool spindle has critical significance for reducing machining errors. However, the classical dynamics method of radial throw based on the rigid body partition method ignores special characteristics of the boring tool spindle, resulting in additional errors regarding radial throw evaluation. Hence, a semi-analytical dynamics method considering the axial length, variable cross-section, and offset distance was proposed to decrease the computational error of the current dynamics model. The mechanism of radial throw was analyzed by the mechanics of materials and mathematical formulas. The Euler-Bernoulli beam theory and partial differential equation method were utilized to derive the dynamics model of the boring tool spindle, and an improved Galerkin variational algorithm was used to resolve the dynamics formulas for the radial throw. Then, the proposed dynamics method was compared with the non-contact displacement measurement and the traditional lumped mass parameter method. The validated results showed that the presented dynamics method had good agreement with the experimental data, and the maximum predictive error was 16.08 μm lower based on the proposed method. Furthermore, the machining precision of holes was also clearly evaluated and discussed using the proposed dynamics method under different processing conditions, and the lower uncertainty of the proposed dynamics method was also demonstrated. As a result, the proposed semi-analytical dynamics method can accurately compute the radial throw and evaluate the machining error in boring technology.
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