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

{"title":"Unveiling surface roughness in Inconel 718 fabricated by LPBF using high-productivity parameters: A dual method exploration","authors":"M. Abruzzo,&nbsp;G. Macoretta,&nbsp;B.D. Monelli,&nbsp;Luca Romoli","doi":"10.1016/j.precisioneng.2025.04.012","DOIUrl":"10.1016/j.precisioneng.2025.04.012","url":null,"abstract":"<div><div>Recent advancements in additive manufacturing and its extension to metallic materials have led to the production of highly technological components with complex geometries and mechanical properties comparable to traditional processes. Despite this, the widespread adoption of additive manufacturing remains limited by low productivity. Additionally, optimizing process parameters to enhance productivity while maintaining high surface quality is challenging due to the intricate relationships between process parameters and surface roughness. This study aims to identify the relationship between process parameters and surface roughness using Inconel 718 specimens produced via laser powder bed fusion. Prismatic specimens were printed using seven combinations of process parameters with progressively increasing productivity. Two methods, traditional profilometry and an optical approach, were compared to assess surface quality under varying process conditions. Results show a strong correlation between process productivity and surface roughness, with higher productivity leading to surface roughness increases up to 200 %. The optical method demonstrated superior sensitivity in detecting sharp peaks and valleys, providing higher detail levels than traditional profilometry. Additionally, the optical method was applied to a practical case where traditional techniques fall short, offering crucial insights for advancing LPBF applications in various industrial sectors.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 783-794"},"PeriodicalIF":3.5,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835185","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":"Machine learning based assessment of audio signal features for chatter identification in high-speed micromilling of thin-walled TC4 alloy","authors":"Sethurao Gururaja,&nbsp;Kundan K. Singh","doi":"10.1016/j.precisioneng.2025.04.011","DOIUrl":"10.1016/j.precisioneng.2025.04.011","url":null,"abstract":"<div><div>The present work identifies the audio signal features that are necessary to detect the chatter onset during high speed micromilling of thin-walled TC4 structure. These features have been derived from the short time Fourier transform of the signal to capture the low magnitude vibration of the micromilling process. Radial micromilling experiments at three different radial depths of cut and four different microphone tilt-angles shows 60° tilt angle as the optimum tilt angle. Entropy, kurtosis and shape factor have been found to be the optimum features based on the principal component analysis. Radial Basis Function has been found to be best suitable kernel with the highest prediction accuracy of 98 % for all the cutting conditions. The optimum features and kernel have been used in support vector machine (SVM) for classification of machining conditions into stable and chatter dominant zone. The presence of chatter marks has been validated using the machined surfaces.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 820-840"},"PeriodicalIF":3.5,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835188","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":"Uncertainty analysis and optimization of contact stress for the centering surface in aviation splines considering surface topography","authors":"Yong Liu ,&nbsp;Jie Qu ,&nbsp;Wenyan Xu ,&nbsp;Fangchao Yan","doi":"10.1016/j.precisioneng.2025.04.008","DOIUrl":"10.1016/j.precisioneng.2025.04.008","url":null,"abstract":"<div><div>The centering surfaces of aviation splines (CSAS) are critical for maintaining alignment and stability in aero-engine rotor systems. Misalignment of CSAS triggers excessive wear, unstable torque transmission, and heightened safety risks. In this study, the deterministic contact mechanics model is established based on the fractal theory to predict the mean contact stress (MCS) of CSAS. Then, the interval model of MCS is derived based on the Chebyshev polynomial expansion and the deterministic contact model, and the constructed model is verified by experimental results. Additionally, the multi-objective uncertainty optimization model was proposed to determine the optimal design strategy of CSAS, with the optimization goal of minimizing both the upper bound of MCS and the uncertainty coefficient. Finally, the uncertainty analysis of MCS is carried out, and optimization results are also discussed in detail. Results indicate that the upper bound of MCS is sensitive to topography parameters and the radial offset, and the optimized solution ensures the upper bound of MCS remains within the safety margin while significantly enhancing system robustness. This study provides effective theoretical guidance for improving the design of centering surfaces and enhancing the load-bearing capacity of aviation splines.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 795-807"},"PeriodicalIF":3.5,"publicationDate":"2025-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835186","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":"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":"A novel method for improving the accuracy of parallel robots based on efficient identification of kinematic parameters","authors":"Shu-mei Zhang ,&nbsp;Jian-wei Ma ,&nbsp;Qian Zhang ,&nbsp;Ze-xu Li ,&nbsp;Guan-lin Li ,&nbsp;Zhen-yuan Jia","doi":"10.1016/j.precisioneng.2025.04.007","DOIUrl":"10.1016/j.precisioneng.2025.04.007","url":null,"abstract":"<div><div>Parallel robots are increasingly used in precision manufacturing and measurement applications. However, factors such as assembly errors and gear clearances can cause the positioning error of the end effector to reach several millimeters, which fails to meet the precision requirements for high-precision machining and measurement. To enhance the positioning accuracy of parallel robots, parameter calibration has become an essential technical approach. As the accuracy of parallel robot systems may gradually decline during long-term operation, regular calibration of the kinematic parameters is particularly important. An efficient and high-precision parameter calibration method for robots is urgently required to avoid disrupting the operation of the measurement system. This paper proposes a two-step method for identifying kinematic parameters based on the kinematic error model of parallel robots, ensuring both calibration accuracy and significant computational efficiency. In the first step, the L2 Regularized Least Squares (L2 RLS) method is used to pre-identify the kinematic parameters, obtaining suboptimal parameter values. Subsequently, the suboptimal values serve as the initial values for the iterative (IT) method, which refines the parameter identification through an iterative process to obtain the optimal parameter values. Numerical simulations have verified the effectiveness of the proposed method, ensuring calibration accuracy while significantly improving computational efficiency. Experimental results further demonstrate that applying the L2 RLS-IT method proposed in this paper reduces the maximum positioning error of the parallel robot from 1.872 mm to 0.294 mm. This significant improvement not only proves the effectiveness of the method, but also plays a crucial role in ensuring the long-term stable operation of parallel robots with high precision.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 24-37"},"PeriodicalIF":3.5,"publicationDate":"2025-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143848269","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":"Compliant micro-nano multi-axis trajectory tracking with nonlinear coupling stiffness using a predefined-time extended state observer","authors":"Jiaqi Liang ,&nbsp;Dunant Halim ,&nbsp;Kean How Cheah ,&nbsp;Chi Zhang","doi":"10.1016/j.precisioneng.2025.04.005","DOIUrl":"10.1016/j.precisioneng.2025.04.005","url":null,"abstract":"<div><div>This work proposes a novel control methodology to achieve high-precision multi-axis coordinated trajectory tracking of a compliant micro-nano positioning stage system with nonlinear coupling stiffness. It addresses the problem of a positioning stage control using compliant parallel mechanisms (CPMs) to undertake complex trajectory tracking, in which multi-axis coupled motions and external disturbances significantly affect the tracking accuracy. To address this, the proposed control method is developed by utilizing the predefined-time extended state observer (PTESO) with linear sliding mode control (SMC), in which the PTESO incorporates the nonlinear stiffness model of CPMs with its stability proven through Lyapunov stability analysis. This method ensures reduced uncertainty in system coupling as disturbance observation converges to the desired accuracy within a predefined time, independent of initial conditions. By solely utilizing position signals, the control system achieves faster and more accurate velocity estimation and disturbance compensation in multi-axis coordinated trajectory tracking, thereby enhancing overall the robustness and dynamic performance. Experimental validation on a 4 PPR (Prismatic-Prismatic-Revolute) planar three-degree-of-freedom compliant stage demonstrates a tracking accuracy of 0.1 μm in a 1-Hz circular trajectory experiment. Compared to SMC with traditional ESO, the proposed scheme significantly reduces the root mean square error (RMSE) by 79.17 %. Notably, significant performance improvements are also observed when tracking other complex trajectories, compared to conventional ESO-based control schemes. The proposed control methodology also effectively mitigates time delays and enables high-precision real-time trajectory tracking at the micro-nano level.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 773-782"},"PeriodicalIF":3.5,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835184","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":"SelfA-inclinometer: A novel device for evaluating the accuracy of tilting rotary tables in five-axis machine tools","authors":"Naoyuki Takahashi ,&nbsp;Tsukasa Watanabe ,&nbsp;Kazuteru Tobita","doi":"10.1016/j.precisioneng.2025.04.009","DOIUrl":"10.1016/j.precisioneng.2025.04.009","url":null,"abstract":"<div><div>In this study, we developed a compact, high-precision angle measuring device called the “SelfA-inclinometer”. The purpose of the SelfA-inclinometer is to enhance the performance of a tilting rotary table, a crucial component of five-axis machine tools responsible for positioning the tilt and rotation axes. This device measures the tilt angle of the working surface of the table, where a workpiece is mounted, as it rotates around the tilt axis. The measurements are highly accurate, providing indicators for improving design, machining, and assembly accuracy. The measuring device comprises a compact self-calibrating rotary encoder (the SelfA), a rotating device, and a precision level. It mounts directly onto the surface to be measured and can measure a wide 360° range with precision on the order of an arc-second (1 arc-second:″ being 1/3600th of a degree). Comparing it with a national standard angle calibration system as a higher-level device revealed a measurement accuracy of ±2 arc-sec or better. Simultaneous measurements were conducted to compare the results with those obtained from a conventional measuring device like a rotary encoder, assessing the validity and superiority of the measurement.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 38-51"},"PeriodicalIF":3.5,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143851983","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 quality and formation mechanism of Ti-6Al-4V by in-situ laser-assisted ball-burnishing","authors":"Siwei Meng ,&nbsp;Jifeng Zhang ,&nbsp;Deshi Kong ,&nbsp;Guangfeng Shi ,&nbsp;Xin Wang ,&nbsp;Hongda Li","doi":"10.1016/j.precisioneng.2025.04.006","DOIUrl":"10.1016/j.precisioneng.2025.04.006","url":null,"abstract":"<div><div>Titanium alloys are widely used in aerospace, rail transportation, and other fields. As components operating in complex environments, high surface finish and excellent fatigue resistance are required. Ball-burnishing is one of the common techniques for surface strengthening of workpieces. However, when dealing with high-strength, low-plasticity materials, ball-burnishing faces issues such as poor surface quality, inadequate strengthening effects, and severe tool wear. Therefore, this study proposes an in-situ laser-assisted ball-burnishing (In-LAB) technology. Unlike the laser pre-assisted ball-burnishing, in this technology, the laser beam is directed to the workpiece machined area by passing through the transparent diamond ball-burnishing tool. The heating and burnishing effects act simultaneously on the workpiece, efficiently utilizing the laser energy and avoiding unnecessary thermal damage. This study has established a finite element model (FEM) for In-LAB and found that, compared to normal ball-burnishing, the maximum residual compressive stress in the workpiece surface increased by 131 %. Through a Taguchi experiment with the objective of minimizing surface roughness, the relevant parameters are: rotation speed 300 r/min, press amount 0.05 mm, feed rate 0.05 mm/r, and laser power 25 W. Compared to normal ball-burnishing, the surface roughness decreased by 51 %, the surface hardness increased by 7.5 %, and tool wear was significantly reduced. This technology combines in-situ laser-assisted machining with ball-burnishing technology. Related research results indicate that it can provide lower surface roughness, higher residual compressive stress, and greater surface hardness. In-LAB technology offers a new approach for surface finishing and strengthening of hard-to-machine materials, expanding the application scope of In-LAM technology.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 151-162"},"PeriodicalIF":3.5,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143873385","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}