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

{"title":"Experimental investigation of actual rolling element distribution in recirculating linear guideways using integrated inductive proximity sensors","authors":"Yutao Lan ,&nbsp;Danny Staroszyk ,&nbsp;Mukesh Moga ,&nbsp;Jens Müller ,&nbsp;Steffen Ihlenfeldt","doi":"10.1016/j.precisioneng.2025.07.014","DOIUrl":"10.1016/j.precisioneng.2025.07.014","url":null,"abstract":"<div><div>The demand for precision in linear motion systems has led to increased efforts to minimize motion errors in linear guideways (LGWs). A significant source of these errors is ball passage vibration, caused by the recirculating nature of rolling elements (REs). Although gaps between REs may arise during operation and alter RE distribution, most studies of LGWs continue to adopt the simplifying no-gap assumption. Prior research has typically inferred RE distribution indirectly through vibration analysis, while the actual distribution under real operating conditions remains unclear, partly due to the lack of practical measurement methods. In this study, we developed a novel experimental approach using integrated inductive proximity sensors to directly measure the RE distribution in the contact zone of an LGW, and investigated the influence of varying loads and velocities on the RE Distribution. The results revealed that RE distribution is irregular and significantly affected by operating conditions, challenging the conventional no-gap assumption and providing new insight for LGW modeling and design.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 706-720"},"PeriodicalIF":3.7,"publicationDate":"2025-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144725010","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":"Design and experimental validation of a novel compliant micro-positioning stage with nonlinear stiffness","authors":"Wei Wang ,&nbsp;Jinchuan Zheng ,&nbsp;Zhihong Man ,&nbsp;Hai Wang ,&nbsp;Xiaoqi Chen ,&nbsp;Yuan Chen","doi":"10.1016/j.precisioneng.2025.07.015","DOIUrl":"10.1016/j.precisioneng.2025.07.015","url":null,"abstract":"<div><div>This article presents a novel design of a piezoelectric actuated stage with variable nonlinear stiffness to achieve active suppression of residual vibrations in response to a step input command. In the stage design, a nonlinear stiffness mechanism with four leaf-shaped compliant legs is proposed, which possesses a more significant and rapid stiffness variation with respect to output displacement than traditional linear stiffness mechanisms. The analysis of the proposed stage design is established on the basis of large deformation theory of beams and analysed by using the pseudo-rigid method. In addition, the response surface method is employed in multi-objective optimization for the key design parameters of the stage. The static and dynamic performance of the stage is evaluated by finite element analysis. Lastly, experiments were conducted on a real prototype of the micro-positioning stage. The experimental results verify that the proposed stage can achieve a continuously adjustable displacement amplification ratio from 3.6 to 10.8 and its first natural frequency from 208 to <span><math><mrow><mn>251</mn><mspace></mspace><mi>Hz</mi></mrow></math></span> owing to the variable stiffness. The results also demonstrate that the stage can achieve self-suppression of the residual vibrations under a step input signal to the piezoelectric actuator.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 745-756"},"PeriodicalIF":3.7,"publicationDate":"2025-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750739","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":"Inspection of edge detection using spatial frequency filtering","authors":"Jingwei Wang ,&nbsp;Tatsuki Otsubo ,&nbsp;Megumu Kuroiwa ,&nbsp;Toshiaki Yasaka ,&nbsp;Soichirou Kanemaru ,&nbsp;Takanori Yazawa","doi":"10.1016/j.precisioneng.2025.07.016","DOIUrl":"10.1016/j.precisioneng.2025.07.016","url":null,"abstract":"<div><div>This study proposes a defect detection system based on spatial frequency filtering to measure edge chipping in two types of tools: straight-edged punching blades and closed-curve punching dies, both made of ultrafine grain cemented carbide. Although different optical configurations were applied to accommodate the geometry of each tool, both systems are based on the same measurement principle using high-pass spatial frequency filtering, and they share a unified image processing algorithm for quantifying edge chipping and suppressing the influence of dust and other noise. A spatial filter is placed at the back focal plane of the Fourier transform lens to block the 0-order ray, forming a clear light-dark-light fringe pattern. Combined with the proposed image processing algorithm, this enables accurate extraction of edge positions and robust evaluation of micro-scale defects. Experiments demonstrated that the developed system could detect edge chipping larger than 1 μm in both types of tools. This research presents a practical and adaptable solution for non-contact defect detection and contributes to advanced quality assurance in industrial blade manufacturing.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 721-728"},"PeriodicalIF":3.7,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144739168","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":"Vacuum compatible spring wire system for mass measurement of vials during lyophilization","authors":"Steven J. Burcat ,&nbsp;Rohan P. Kadambi ,&nbsp;Lorenzo Stratta ,&nbsp;Richard D. Braatz ,&nbsp;Roberto Pisano ,&nbsp;Bernhardt L. Trout ,&nbsp;Alexander H. Slocum","doi":"10.1016/j.precisioneng.2025.07.007","DOIUrl":"10.1016/j.precisioneng.2025.07.007","url":null,"abstract":"<div><div>Pharmaceutical lyophilization (vacuum freeze-drying) stabilizes aqueous formulations, commonly in vials, by removing 99.9% of their water. Failure to remove enough water leads to unstable products, so measuring the amount of water removed throughout the process is critical. Current technologies can measure the total rate of water removal from a batch of vials or destructively measure the final water content of sample vials, but they cannot monitor individual vials in situ. An in-line measurement for the water content of every vial would assess variation in the drying process, enabling process improvements and vial-specific optimizations. This work presents a mass sensor that achieves this individual vial measurement throughout the lyophilization process.</div><div>This mass sensor consists of two partial helical springs holding a suspended vial. As water sublimates from the vial during drying, the position and orientation of the free ends of the helical springs change. This change is amplified by sensing arms and measured by a camera outside of the vacuum chamber. Optical fiducials at the ends of the sensing arms enable high-fidelity measurement of the amplified motion. This sensor provides individual vial mass information, allowing tracking of its sublimation rate, without affecting the lyophilization process.</div><div>The sensor design was evaluated by building ten sensors for 10R vials with a 3 mL fill. After calibration, these sensors achieved a median offline testing error of 13 mg, which improved to 6.5 mg when calibration coefficients were updated using the maximum a posteriori method. When the sensors were tested in a lyophilization environment, the median error in their final mass measured increased to 50 mg, likely due to micro-slip of the sensor assembly contact regions between measurements introduced hysteresis. Nevertheless, per vial sublimation rates are measured accurately and used to infer drying endpoints.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 729-744"},"PeriodicalIF":3.7,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750738","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":"Dimension optimisation of a dual-arm robot for enhanced stiffness in task-dependent polishing operations","authors":"Si Huang ,&nbsp;Jianzhong Yang ,&nbsp;Haotian Wu ,&nbsp;Xiao Ning ,&nbsp;Binhui Pan","doi":"10.1016/j.precisioneng.2025.07.021","DOIUrl":"10.1016/j.precisioneng.2025.07.021","url":null,"abstract":"<div><div>To address the issue of poor absolute positioning accuracy caused by the low stiffness of serial robot arms, we previously proposed a novel dual-arm robot (DAR) by optimising the configuration of a traditional robot. Building upon this foundation, the present study proposes a dimension optimisation method aimed at further enhancing the stiffness performance of the DAR in task-dependent polishing operations. A new stiffness index, the Polishing Deformation Index (PDI), is proposed to quantitatively evaluate the robot's stiffness under constant-force polishing conditions. The PDI considers both contact force and gravitational effects exerted by the tool and the workpiece. Furthermore, the maximum PDI (MPDI) is employed to characterise the stiffness along the complete polishing trajectory. A dimension optimisation model targeting the minimisation of MPDI and the singularity index is established, incorporating constraints such as joint range limits, kinematic feasibility and trajectory smoothness. Both simulation and experimental results demonstrate the effectiveness of the proposed index and optimisation strategy. Specifically, the surface roughness of the polished blades is reduced by over 25 %.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 692-705"},"PeriodicalIF":3.7,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144725009","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":"Surface pretreatment methods for cemented carbide substrates of the coated cutting tools: A review","authors":"Mingfeng Ke ,&nbsp;Lanying Shao ,&nbsp;Yuyang Chen ,&nbsp;Hengmei Yuan ,&nbsp;Jiahuan Wang ,&nbsp;Honglin Li ,&nbsp;Saurav Goel ,&nbsp;Xingsheng Wu ,&nbsp;Binghai Lyu","doi":"10.1016/j.precisioneng.2025.07.019","DOIUrl":"10.1016/j.precisioneng.2025.07.019","url":null,"abstract":"<div><div>Surface pretreatment of cemented carbide substrates is utilized to eliminate defects such as burrs, chips, and grinding marks resulting from the grinding process. It also optimizes the physicochemical properties of the coating-substrate interface and enhances the adhesion strength between the coating and substrate, ultimately improving cutting performance and extending the service life of cutting tools. This research provides a comprehensive and systematic review of advancements in tool pretreatment technologies, outlining visions for their future development. Initially, it offers a concise overview of commonly utilized coating materials for cemented carbide coated cutting tools. Subsequently, it delves into the mechanisms through which the surface characteristics of cemented carbide substrates influence the adhesion properties of coatings. Building upon existing processing technologies, new pretreatment methods are explored, with a systematic summary and analysis of their principles, advantages, and limitations. These pretreatment methods are categorized into common and non-conventional methods. A comparative analysis of these methods is conducted, considering factors such as surface quality, coating adhesion strength, processing efficiency, processing difficulty, cost, and general availability. Finally, the prospective trajectory for the evolution and advancement of tool pretreatment technologies is delineated in the research.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 663-691"},"PeriodicalIF":3.5,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144704128","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":"Tool wear mechanisms and failure modes in side milling of ultra-high strength steel under different sustainable cooling conditions","authors":"Bangfu Wu ,&nbsp;Guoliang Liu ,&nbsp;Minxiu Zhang ,&nbsp;Wenfeng Ding ,&nbsp;Biao Zhao","doi":"10.1016/j.precisioneng.2025.07.022","DOIUrl":"10.1016/j.precisioneng.2025.07.022","url":null,"abstract":"<div><div>Ultra-high strength steels (UHSSs) are extensively utilized in the aerospace field because of their exceptional material properties. However, in green manufacturing processes, the issue of rapid tool wear hampers machining efficiency and raises production costs. The atomization modes of cutting fluids are considered a sustainable and effective method for cooling and lubrication, significantly reducing tool wear. The current paper carried out the comparative milling experiments on UHSSs to identify appropriate machining conditions, including dry machining, high-pressure air cooling (HPAC), air atomization of cutting fluid (AACF), and ultrasonic atomization of cutting fluid (UACF). The wear behavior of the coated carbide tool was investigated under various sustainable cooling conditions, focusing on tool life, tool wear types, wear mechanisms, and failure mode. Results showed that the lubrication ability in the milling process was more crucial than the cooling performance for improving the tool life. The UACF process extended the tool life by 19.2 % compared to AACF conditions. This was attributed to the fact that ultrasonic atomization enables the production of small droplet diameter, uniform droplet distribution, and high droplet number density, thereby enhancing the cooling and lubrication capabilities of the droplets. The predominant wear types on the coated tool encompassed abrasion, adhesion, coating detachment, and chipping. Additionally, the primary wear mechanisms observed on both the rake face and flank face were abrasive wear, adhesive wear, and oxidative wear regardless of cooling conditions. The failure mode of the coated carbide tool was attributed to the transgranular fracture of WC grains and ductile fracture of Co binder phase, leading to sudden tool breakage.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 640-652"},"PeriodicalIF":3.5,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703392","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":"Material removal and damage formation mechanisms during ultrasonic vibration-assisted grinding of high volume fraction SiCp/Al composites","authors":"Xuebin Yao ,&nbsp;Jianhao Peng ,&nbsp;Ruihong Zhou ,&nbsp;Rui Wang ,&nbsp;Guojun Li ,&nbsp;Wenfeng Ding ,&nbsp;Biao Zhao","doi":"10.1016/j.precisioneng.2025.07.023","DOIUrl":"10.1016/j.precisioneng.2025.07.023","url":null,"abstract":"<div><div>High volume fraction silicon carbide particle-reinforced aluminum matrix (SiC_p/Al) composites are applied in aerospace industries owing to their superior properties. However, the hardness, brittleness, and uneven distribution of SiC particles often lead to fluctuations in grinding force and surface damage during conventional grinding (CG). At high volume fraction, the overall brittleness of SiC particles increases, resulting in a higher grinding force and exacerbated machining defects. Ultrasonic vibration-assisted grinding (UVAG) has shown significant advantages in machining brittle and hard materials. In this study, comparative experiments were performed on SiCp/Al composites with 60 vol% SiC particles using a single abrasive grain under CG and UVAG conditions, aiming to reveal the material removal and damage formation mechanisms. The results indicate that UVAG reduced the normal grinding force <em>F</em>_n by 19.8 %–29.3 % and the tangential grinding force <em>F</em>_t by 21.3 %–30.1 %, while also decreasing the specific grinding energy by 26.7 %–35.4 % compared to CG. Additionally, the scratching quality was also improved, with the surface roughness <em>S</em>_a reduced by 16.0 %–23.2 % and the average pile-up ratio lowered by 17.1 %–20.8 %. UVAG also effectively suppressed radial crack propagation due to the dense interactions between SiC particles, which inhibited slip and reduced severe subsurface damage. This study promotes the practical application of UVAG in high volume fraction SiC_p/Al composites.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 625-639"},"PeriodicalIF":3.5,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703391","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":"Electrochemistry assisted shear thickening polishing of Ti-6Al-4V","authors":"Zewei Tang ,&nbsp;Mingfeng Ke ,&nbsp;Jiahuan Wang ,&nbsp;Lanying Shao ,&nbsp;Binghai Lyu","doi":"10.1016/j.precisioneng.2025.07.020","DOIUrl":"10.1016/j.precisioneng.2025.07.020","url":null,"abstract":"<div><div>In order to obtain a high-quality Ti-6Al-4V surface, an electrochemistry assisted shear thickening polishing (E-STP) method is proposed in this paper. In order to investigate the material removal synergistic effect of mechanical and electrochemical in the polishing process, this paper mainly investigates the effects of current, voltage, and polishing speed on surface roughness (<em>S</em>_a) and material removal rate (MRR). The results show that at the same polishing speed, as the current intensity or voltage intensity increases, the surface material removal rate first rises and then falls, and the surface roughness <em>S</em>_a first falls and then rises. At a polishing speed of 80 rpm with a 160 mA current, the optimal synergy between the electrochemical effect and the shear thickening effect was achieved, resulting in the highest MRR of 543.4 nm/min and the lowest surface roughness Sa of 1.4 nm. As polishing speed increases, a higher current density is required to achieve the highest MRR and lowest <em>S</em>_a. This is because faster speeds enhance mechanical removal, necessitating stronger electrochemical action to maintain balance. According to the EDS results, at 80 mA and 80 rpm, the oxide content is 0, indicating a balance between mechanical and electrochemical effects, leading to efficient material removal and optimal surface roughness. At 160 mA, the oxide content is 4.57 %, with the electrochemical effect slightly stronger, achieving the optimal synergy and polishing results.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 609-624"},"PeriodicalIF":3.5,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703390","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":"Wet etching after femtosecond laser machining for efficient fabrication of consistent inverted pyramid microstructures on monocrystalline silicon surfaces","authors":"Qingwei Wang ,&nbsp;Peng Yao ,&nbsp;Haizhong Wang ,&nbsp;Xuerui Xin ,&nbsp;Dongkai Chu ,&nbsp;Shuoshuo Qu ,&nbsp;Hongtao Zhu ,&nbsp;Hanlian Liu ,&nbsp;Bin Zou ,&nbsp;Chuanzhen Huang","doi":"10.1016/j.precisioneng.2025.07.017","DOIUrl":"10.1016/j.precisioneng.2025.07.017","url":null,"abstract":"<div><div>Monocrystalline silicon is an important semiconductor material. Monocrystalline silicon with appropriate surface structure has been used in the field of microelectronics and microsolar cells due to its improved mechanical and optical properties. However, due to its brittle and hard properties, the high-quality preparation of microstructures is difficult. In this study, femtosecond laser-assisted wet chemical etching was utilized to fabricate well-defined inverted pyramidal etch pits and array structures on monocrystalline silicon surfaces, while the actual angle between the (100) and (111) crystallographic planes was determined. Firstly, the morphology of ablation holes under different laser parameters was studied. Secondly, wet etching was conducted at 20 °C and 80 °C to investigate the morphology evolution of inverted pyramid etching pits. The optical properties of monocrystalline silicon were tested. The experimental results demonstrate that the inverted pyramid-structured m-Si exhibits an absorptivity exceeding 95 % within the wavelength range of 400–900 nm. This is of great significance for improving the optical performance of monocrystalline silicon.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 600-608"},"PeriodicalIF":3.5,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144702842","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}