Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology最新文献

{"title":"Detecting microscale surface imperfections in powder bed fusion through light scattering and machine learning – validation of inspection principles","authors":"Ahmet Koca ,&nbsp;Helia Hooshmand ,&nbsp;Richard Leach ,&nbsp;Mingyu Liu","doi":"10.1016/j.precisioneng.2025.04.010","DOIUrl":"10.1016/j.precisioneng.2025.04.010","url":null,"abstract":"<div><div>Microscale surface imperfections in laser beam powder bed fusion (PBF-LB) additively manufactured parts, such as balling, spattering, and surface pores, can substantially reduce component quality but are difficult to detect with current real-time measurement and monitoring methods. This paper introduces a novel, rapid, and cost-effective method for detecting microscale surface imperfections in PBF-LB, utilising light scattering combined with machine learning (ML) algorithms. In the proposed method, a laser beam illuminates the measured surface, and the scattered light is captured and analysed to detect surface imperfections. The scattering patterns, which are associated with the illuminated surface and the configuration of the setup, are used to train unsupervised ML algorithms, including autoencoders and anomaly detection models, to classify surfaces as either uniform, without any imperfections or non-uniform, with imperfections. The ML models were trained on simulated scattering patterns of synthetic surfaces generated by a generative adversarial network (GAN) and validated on experimental datasets. The use of unsupervised models eliminates the need for data labelling, whilst the use of simulated and synthetically generated data reduces the time required for actual experiments and data collection. Experimental validation demonstrates that the most effective trained ML model achieved a classification accuracy of over 97 %, highlighting the potential of this technique for detecting microscale surface imperfections. This paper demonstrates the capability of our method to detect such imperfections on PBF-LB surfaces as an ex-situ process. Nonetheless, with further development, this approach has the potential to be adapted as on-machine and real-time defect detection method, by integrating the illumination source into a commercial PBF-LB machine and capturing scattered light information for real-time quality monitoring during the manufacturing process.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 761-772"},"PeriodicalIF":3.5,"publicationDate":"2025-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143823997","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Model-free tool path modification in ultra-precision diamond turning of freeform surfaces using iterative learning control","authors":"Xinquan Zhang,&nbsp;Hao Wu,&nbsp;Yangqin Yu,&nbsp;Zelong Jia,&nbsp;Xiangyuan Wang,&nbsp;Mingjun Ren,&nbsp;Limin Zhu","doi":"10.1016/j.precisioneng.2025.04.003","DOIUrl":"10.1016/j.precisioneng.2025.04.003","url":null,"abstract":"<div><div>With the aid of the commercial ultra-precision machine tool, the tool servo diamond turning process provides stable and deterministic material removal, meeting the demands for mass production of high-end freeform surface optics. However, in relatively high-speed applications, the machining accuracy is limited by the heavy servo axes, even within the working bandwidth of −3 dB. Therefore, to facilitate the industrial adoption of diamond turning, a cost-effective and user-friendly programming strategy is essential for enhanced motion accuracy in commercial machine tools. This work proposes a model-free tool path modification strategy using iterative learning control (ILC), which adjusts tool path amplitude iteratively based on the error data of servo axes. By aligning the geometry-based tool path with the dynamic properties of the servo axes, such adjustments reduce tracking errors caused by frequency-based phase lag and amplitude variation effects in high-speed applications. Additionally, this strategy eliminates the need for additional complex equipment or model identification, making it well-suited for industrial applications. The fundamental principle of the proposed method is first presented, followed by a demonstration of its convergence. A series of validation experiments are conducted through trajectory tracking and diamond turning. Experimental results indicate that trajectory tracking achieves a reduction of approximately 60 % in peak-to-valley error and about 80 % in root-mean-square error with the proposed strategy. For diamond turning experiments on sinusoidal grid surfaces, the form error is significantly reduced from 903 nm to 527 nm. Further experiments confirm the long-term effectiveness of the ILC-based tool path modification strategy in high-speed applications, offering valuable insights for industrial use.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 736-748"},"PeriodicalIF":3.5,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143799400","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing the efficiency and determinacy of in-situ monoscopic phase measuring deflectometry by Bayesian approach","authors":"Yunuo Chen,&nbsp;Wei Lang,&nbsp;Ting Chen,&nbsp;Xingman Niu,&nbsp;Xiangchao Zhang","doi":"10.1016/j.precisioneng.2025.04.002","DOIUrl":"10.1016/j.precisioneng.2025.04.002","url":null,"abstract":"<div><div>Phase measuring deflectometry is a promising technique for in-situ measurements of optical surfaces. However, the cumbersome system calibration remains a major negative factor limiting its measurement efficiency and determinacy in practical applications. Especially when ray tracing and numerical optimization are employed to assist system calibration and form reconstruction, numerical instability and local optimum problems arise. To address these challenges, a holistic calibration and form reconstruction framework is proposed based on the Bayesian approach. The efficiency decrement caused by sophisticated system calibration is resolved via automatic camera calibration and spherical mirror-based geometrical calibration. The instability issue is tackled by incorporating constraints derived from prior distributions of configuration parameters. Furthermore, a complete uncertainty propagation chain is established. Experimental results demonstrate that the proposed method boosts efficiency while guaranteeing robustness, and enhances the determinacy of measurement results.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":""},"PeriodicalIF":3.5,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791962","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Damage-free and ultra-smooth chemical mechanical polishing of calcium fluoride crystal surfaces","authors":"Jiaqi Li ,&nbsp;Haixiang Hu ,&nbsp;Guanbo Qiao ,&nbsp;Erhui Qi ,&nbsp;Yang Bai ,&nbsp;Fukun Li ,&nbsp;Zhenyu Liu ,&nbsp;Lingzhong Li ,&nbsp;Zhifan Yang ,&nbsp;Xuejun Zhang","doi":"10.1016/j.precisioneng.2025.04.001","DOIUrl":"10.1016/j.precisioneng.2025.04.001","url":null,"abstract":"<div><div>Calcium fluoride (CaF₂) crystal is an important optical material in ultraviolet lithography systems. The low hardness of CaF₂ results in surface damage and poor roughness during surface processing, which is a primary reason for laser-induced damage and can reduce its lifetime. This paper investigates the removal characteristics of CaF₂ crystal materials using chemical mechanical polishing (CMP) technology to achieve damage-free and ultra-smooth surface. The interaction between cerium oxide, water, and CaF₂ crystals is analyzed through molecular dynamics simulations to reveal the chemical reaction mechanisms during the CMP process, as well as the chemical action between abrasive and CaF₂ substrate is revealed. The relationship model for the indentation depth in CaF₂ is established. Based on this model, methods for damage restrain and ultra-smooth are proposed. Experimental results show that the theoretical model is correct and the balance between chemical removal and mechanical removal is achieved. Finally, a damage-free and ultra-smooth surface with surface finish grade of 0/0 and surface roughness better than 0.1 nm RMS is obtained. The research findings offer a robust framework for the ultra-precision polishing of CaF₂ crystals and provide critical technical support for their applications in ultraviolet (UV) optical systems.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 725-735"},"PeriodicalIF":3.5,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791850","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Advancing gear manufacturing: A comprehensive review of gear skiving technology","authors":"Shuaijie Zhao ,&nbsp;Yuhong Du ,&nbsp;Jia Li ,&nbsp;Yongquan Jin ,&nbsp;Shuai Wang ,&nbsp;Xinlong Li","doi":"10.1016/j.precisioneng.2025.03.033","DOIUrl":"10.1016/j.precisioneng.2025.03.033","url":null,"abstract":"<div><div>Gear skiving technology is a highly efficient machining method compared to other gear manufacturing techniques. This paper presents a comprehensive review of gear skiving technology. First, the research progress in this field is introduced. Then, key research areas are systematically summarized, including machining principles, cutting process simulation and mathematical modeling, the influence of parameters on the process, tool design, error analysis and correction, tool manufacturing, tool life and wear, as well as related research methods and achievements. Furthermore, this review identifies several critical problems in current studies, such as the limited accuracy of simulation models in describing actual machining processes, the lack of consideration of the interaction between parameters, and the insufficient generality of tool design approaches. Finally, future research directions are outlined, including the development of more accurate multi-physics coupled simulation models, the realization of real-time error compensation, and the integration of artificial intelligence for tool wear monitoring and lifespan prediction. This paper makes up for the gaps in the field of gear skiving technology reviews, not only comprehensively presenting the development history, main research directions, and current challenges of this technology, but also providing a valuable reference for researchers and engineering applications.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 657-674"},"PeriodicalIF":3.5,"publicationDate":"2025-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785693","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Real-time control parameter update and stochastic tool wear monitoring framework for nonlinear micro-milling process","authors":"Pengfei Ding ,&nbsp;Zhijie Liu ,&nbsp;Xianzhen Huang ,&nbsp;Chengying Zhao ,&nbsp;Yuxiong Li","doi":"10.1016/j.precisioneng.2025.03.031","DOIUrl":"10.1016/j.precisioneng.2025.03.031","url":null,"abstract":"<div><div>In modern manufacturing, micro-milling technology encounters challenges such as unpredictable tool wear and dynamic variations in cutting parameters, which adversely affect machining accuracy and safety. This study presents a nonlinear micro-milling mechanical model that combines tool runout, chip separation, stochastic tool wear, and tool-tip trajectory change to accurately predict cutting forces. The Hippopotamus optimization algorithm is introduced to address the particle impoverishment problem in coefficient recognition and improve the real-time update efficiency of the cutting model. Additionally, a DASAT network model combining Recurrent Neural Networks and Convolutional Neural Networks with an attention mechanism is proposed for more precise tool wear prediction, achieving lower prediction error rates compared to LSTM/TCN-based methods. By correlating the predicted tool state with the wear threshold, the system can perform active maintenance interventions to reduce tool failures. The experiment demonstrates that the machining based on the proposed framework can improve surface accuracy while maintaining a stable cutting state, ensure the safety and reliability of the micro-milling process, and provide strong support for process optimization and equipment maintenance.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 638-656"},"PeriodicalIF":3.5,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767963","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental study on in-situ laser-assisted diamond turning of single crystal germanium","authors":"Chunyang Zou ,&nbsp;Guangfeng Shi ,&nbsp;Siwei Meng ,&nbsp;Deshi Kong ,&nbsp;Dong Yao","doi":"10.1016/j.precisioneng.2025.03.032","DOIUrl":"10.1016/j.precisioneng.2025.03.032","url":null,"abstract":"<div><div>For typical optical crystals like silicon and germanium, conventional ultra-precision machining ensures high machining quality but significantly reduces efficiency. Consequently, in-situ laser-assisted turning has emerged as a viable alternative. This study focuses on the single crystal germanium (111) surface and establishes a temperature-dependent model for calculating the critical cutting thickness of ductile-to-brittle transition. Orthogonal experiments were conducted on in-situ laser-assisted turning, followed by variance analysis, signal-to-noise ratio analysis, and mean analysis of the post-machining surface roughness. The contribution of each machining parameter to reducing surface roughness is as follows: rake angle &gt; laser power &gt; spindle speed &gt; feed rate &gt; cutting depth. The optimized parameter combination identified is: rake angle of −35°, laser power of 10 W, spindle speed of 2000 r/min, feed rate of 1 μm/r, and cutting depth of 1 μm. Machining with these parameters reduced surface roughness by 22.4 % compared to conventional machining under the same conditions, resulting in a surface free of fractures and pits.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 608-622"},"PeriodicalIF":3.5,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143761132","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Magnetic characteristics and experimental investigations of eccentric magnetic honing for thick-walled, small-aperture stainless steel pipes","authors":"Zhao-kun Yan ,&nbsp;Yong-gang Li ,&nbsp;Sheng-qiang Yang ,&nbsp;Xiu-hong Li ,&nbsp;Xin-gai Yao ,&nbsp;Tong-yi Liu ,&nbsp;Zhe Tong","doi":"10.1016/j.precisioneng.2025.03.021","DOIUrl":"10.1016/j.precisioneng.2025.03.021","url":null,"abstract":"<div><div>To tackle the polishing challenges posed by the inner surface of thick-walled, small-aperture stainless steel pipe, the concept of eccentric magnetic honing technology is proposed. The force and motion of the process are realized by the attraction of the outer magnetic pole to a pair of permanent magnets inside the magnetic tool. In order to obtain the magnetic force and torque information of the permanent magnet inside the magnetic tool quickly and accurately, the equivalent magnetic charge method is used to establish the numerical model, and the magnetic force and torque expressions of the outer magnetic pole in translational and rotational motion modes are further derived. On this basis, the finite element model is established and the numerical model for validation. The results show that the modified equivalent magnetic charge model can predict the magnetic force quickly and accurately. Then, the influence of the outer magnetic pole size on the magnetic force and torque is studied, and the influence on the driving point is further explored by combining the kinematic equation. Finally, the preliminary process experiments show that the process can complete the polishing of thick-walled, small-aperture stainless steel inner surfaces.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 700-724"},"PeriodicalIF":3.5,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791849","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Theoretical and experimental characterization of an active ferrofluid pad bearing for nanopositioning","authors":"Pongsiri Kuresangsai,&nbsp;Matthew O.T. Cole,&nbsp;James Moran","doi":"10.1016/j.precisioneng.2025.03.018","DOIUrl":"10.1016/j.precisioneng.2025.03.018","url":null,"abstract":"<div><div>The use of actively controlled smart fluids for high-precision manipulation holds significant promise. This paper introduces a novel active ferrofluid pad bearing capable of controlling motion of a platform with nano-scale accuracy. The actuation force and stiffness of the bearing are generated through the fluid magnetization pressure, which can be controlled precisely by adjusting the current through an electromagnetic coil. The combination of passive and active flow properties of the ferrofluid enable the system to achieve fast and precise motion without the need for complicated control strategies or system design, thereby providing a simple and cost-effective solution. A theoretical model of the active bearing system, including both viscous and magnetic pressure fields, is derived from first principles and validated through experimental testing. Based on the modeling results, an optimized PI control system is proposed to achieve a suitable balance of position error minimization and noise attenuation. The experimental results show the capability for motion control within 5 nanometers resolution. The results also show that matching the system and controller design with the viscosity of the ferrofluid is crucial for achieving high performance, as the passive damping effects from the fluid can be leveraged to enhance stability and disturbance rejection.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 596-607"},"PeriodicalIF":3.5,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143761131","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of a large-scale standard device for calibration of high-precision spherical coordinate scanning measurement systems","authors":"Anbin Sun ,&nbsp;Jihu Wang ,&nbsp;Wenxu Qian ,&nbsp;Ling Wang ,&nbsp;Jingjing Fan ,&nbsp;Tieze Cao ,&nbsp;Ting Gao ,&nbsp;Zhi Zou ,&nbsp;Lijun Xu ,&nbsp;Liqun Ma ,&nbsp;Li Zhang","doi":"10.1016/j.precisioneng.2025.03.030","DOIUrl":"10.1016/j.precisioneng.2025.03.030","url":null,"abstract":"<div><div>The rapid advancement of high-precision spherical coordinate scanning measurement systems (HP-SCSMSs) has significantly improved the efficiency and accuracy of profile measurements for complex curved parts, such as aircraft wings, fuselages, rocket bodies, and wind turbine blades. However, the calibration and performance evaluation of HP-SCSMSs remain challenging, as both internal geometric errors and external error sources can contribute to inaccuracies in the resulting 3D point clouds. To address these challenges, a large-scale curved surface standard device has been designed and assembled. This device provides a physical reference for evaluating HP-SCSMSs and facilitates comprehensive calibration of HP-SCSMSs. This paper details the design, assembly, and verification of the standard device. During the design phase, the careful consideration is given to the surface shape and the adjustment strategy for the surface panels to ensure the device could simulate a variety of scanning objects and conditions. To mitigate the effects of temperature changes on measurement accuracy, an innovative independent suspension and radial guide structure is implemented, effectively reducing the impact of thermal deformation. During assembly, advanced high-precision measurement techniques are employed to ensure the precise alignment and stability of each component. Finally, to verify the long-term stability of the standard device, three measurements of its concave panel using a laser tracker are taken over a period of nine months. The measured data are compared with the previously constructed model, showing a maximum Root Mean Square (RMS) of 0.009 mm. The developed large-scale standard device provides a reliable standard for evaluating and calibrating HP-SCSMSs, addressing both internal and external error sources, and lays the groundwork for the development and refinement of industry standards for HP-SCSMSs.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 675-692"},"PeriodicalIF":3.5,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785003","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}