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

{"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":"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":"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":"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}

{"title":"A two-axis Lloyd's mirror interferometer with elastically bent mirrors for fabrication of variable-line-spacing scale gratings","authors":"Chenguang Yin,&nbsp;Ryo Sato,&nbsp;Satoshi Kodaka,&nbsp;Hiraku Matsukuma,&nbsp;Wei Gao","doi":"10.1016/j.precisioneng.2025.03.029","DOIUrl":"10.1016/j.precisioneng.2025.03.029","url":null,"abstract":"<div><div>A cost-effective and flexible laser interference lithography system with an exposure area of approximately 100 mm × 100 mm for fabrication of two-axis variable-line-spacing (VLS) scale gratings is newly proposed and developed. Two elastically bent mirror (EBM) modules, each of which is composed of an elastically bent mirror and a loading mechanism, are integrated into a non-orthogonal two-axis Lloyd's mirror interferometer. The deflections of the <em>X</em>- and <em>Y</em>-EBMs can generate nonlinear components in the wavefronts of the <em>X</em>- and <em>Y</em>-beams, resulting in a stationary interference fringe field with variable pitches along the <em>X</em>- and <em>Y</em>-directions, respectively. The pitch specifications (the center pitch and the pitch variation range) of the grating can be adjusted by changing the corresponding module parameters (the tilt angle and the applied load). Theoretical calculations and experimental results indicate that for EMBs with a dimension of 450 mm (length) × 250 (width) × 2 mm (thickness), the center pitch can be linearly adjusted within the range of 680 nm–1290 nm with respect to a tilt angle range of 10°, while the pitch variation range is independently adjustable from 60 nm to 130 nm with respect to an applied load range of 8 N. Two-axis VLS grating structures with a center pitch of 1000 nm and a pitch variation of ±45 nm are successfully fabricated over a fabrication area of 100 mm × 100 mm, which demonstrates the feasibility of the developed system.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 623-637"},"PeriodicalIF":3.5,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767962","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Chatter detection and suppression system integrated with the CNC lathe","authors":"Bartosz Powałka ,&nbsp;Jan Tomaszewski","doi":"10.1016/j.precisioneng.2025.03.022","DOIUrl":"10.1016/j.precisioneng.2025.03.022","url":null,"abstract":"<div><div>Chatter vibrations lead to poor surface finish and tool wear. Reliable chatter detection is a prerequisite for its prevention. This paper presents a lathe spindle equipped with displacement sensors to detect chatter vibrations. The sensors are integrated into the machine tool through communication with the CNC control system and are protected from cutting fluids and chips. The data collected during machining are used to calculate the chatter indicator, which is based on the multiple samples per revolution method. The use of displacement sensors has made it possible to define an additional indicator that distinguishes between the appearance of chatter vibrations and the entry or exit of the workpiece. The transmissibility function is used to evaluate the vibration at the tool tip, which contributes to the autonomy of the chatter detection. Numerous experimental tests have confirmed the high reliability of the proposed indicators, which helps to avoid false alarms. When chatter vibrations are detected, an autonomous algorithm for regulating the spindle speed is activated. The stable speed is selected based on the natural frequency, which is determined using the experimentally estimated frequency of chatter vibrations. Cutting tests have confirmed the effectiveness of the algorithms developed.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 526-544"},"PeriodicalIF":3.5,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143737789","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":"Research on assembly performance prediction, optimal design, and adjustment methods for precision opto-mechanical system","authors":"Shenhua Ma,&nbsp;Xiaokai Mu,&nbsp;Zhihao Fan,&nbsp;Yuchen Ai,&nbsp;Zibo Sun,&nbsp;Qingchao Sun","doi":"10.1016/j.precisioneng.2025.03.026","DOIUrl":"10.1016/j.precisioneng.2025.03.026","url":null,"abstract":"<div><div>With the rapid development of optical technology, opto-mechanical systems are widely applied in space exploration, high-energy laser applications, and ultra-precision laser processing and measurement. The precise assembly of optical components is a key factor in ensuring the performance of opto-mechanical systems. Therefore, improving the assembly performance of optical systems has become one of the hot topics in optical research. The research on the assembly performance of existing opto-mechanical systems primarily emphasizes predictive model construction, optimization of structural stiffness, assembly process planning, and automation equipment development. These studies typically address only one or a few specific issues and lack a systematic review of the overall development status and technical interrelations of high-performance assembly technologies for opto-mechanical systems. Moreover, technology that integrates “design, assembly, measurement, and adjustment” to enhance optomechanical systems has yet to be developed. Centered on two key performance metrics of opto-mechanical systems—pointing accuracy and surface distortion, this paper reviews the theoretical frameworks and technical progress of related predictive models, addressing three aspects: current research status, error analysis, and quantitative performance description methods. Secondly, from the perspectives of optimization design and adjusting processes, this paper summarizes the main technical approaches for improving optical performance, comparing, and applying deterministic and uncertainty optimization methods for optical system error factors, and analyzes their applicability and limitations. Subsequently, this paper focuses on the development status of intelligent assembly and adjustment technologies and analyzes their role in improving assembly accuracy from two aspects: assembly processes and assembly equipment. Finally, this paper concludes by summarizing the findings and envisioning future directions, offering a clear learning pathway for novices in the field of opto-mechanical system performance research, presenting specialists with perspectives on key technologies and avenues for further exploration, and providing a valuable reference for practical engineering applications and future studies, facilitating new technological breakthroughs and theoretical advancements.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 545-570"},"PeriodicalIF":3.5,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747788","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 research on surface formation during 3D ultrasonic vibration-assisted turning","authors":"Shiyu Wei,&nbsp;Caoyuan Wei,&nbsp;Zhilun Zhou,&nbsp;Yifei Xu","doi":"10.1016/j.precisioneng.2025.03.028","DOIUrl":"10.1016/j.precisioneng.2025.03.028","url":null,"abstract":"<div><div>A comprehensive study on the surface formation mechanism of three-dimensional ultrasonic vibration-assisted turning (3D-UVAT) is a major contribution to improving the finished surface quality and expanding the functional surface. In this study, the influence of different machining parameters on the output surface was thoroughly investigated with the critical cutting speed. In addition, the contribution of the plastic side flow of the material and the elastic recovery of the material to the surface roughness under different parameter conditions was calculated. The theoretical analysis was confirmed by experiments. Overall, this study sheds new light on 3D-UVAT.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 461-473"},"PeriodicalIF":3.5,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143716037","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":"Nd-Fe-B micro-magnet machined by diamond wire sawing: An approach on surface integrity and magnetic properties","authors":"Erick Cardoso Costa ,&nbsp;Paulo Antônio Pereira Wendhausen ,&nbsp;Fabio Antonio Xavier","doi":"10.1016/j.precisioneng.2025.03.025","DOIUrl":"10.1016/j.precisioneng.2025.03.025","url":null,"abstract":"<div><div>This study investigates the effect of diamond wire sawing on the surface integrity and magnetic properties of machined Nd-Fe-B micro-magnets. A diamond wire saw was employed to cut micro-magnets from larger sintered Nd-Fe-B magnets, varying wire cutting speed (v_c), feed rate (v_f), and micro-magnet thickness. Surface integrity and magnetic properties of micro-magnets were analyzed. The results showed that surface morphology presented microgrooving and microcutting predominance at higher v_c, while crater formation increased with higher v_f. The minimum surface roughness values achieved were S_a = 0.32 μm, S_q = 0.41 μm, and S_z = 5.93 μm. Subsurface damage included Nd₂Fe₁₄B grain pullout and intergranular microcracks, and chips exhibited a fragment-like morphology. A micro-magnet thickness of 80.4 ± 4.6 μm was successfully obtained at v_c = 5 m/s, whereas cutting micro-magnets &lt;200 μm was challenging at 15–25 m/s. A reduction in micro-magnet thickness led to a decline in magnetic properties: for the 80.4 ± 4.6 μm micro-magnet, H_cj was 1209.5 kA/m and (BH)_max was 217.3 kJ/m³, whereas for the 495.0 ± 8.2 μm micro-magnet, H_cj reached 1403.4 kA/m and (BH)_max was 286.2 kJ/m³. The decrease in magnetic properties correlated with an increase in the machined surface-to-volume ratio. These findings indicate that diamond wire sawing is a promising micromachining process for Nd-Fe-B micro-magnets, ensuring high surface quality while maintaining excellent magnetic properties.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"94 ","pages":"Pages 505-525"},"PeriodicalIF":3.5,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143737765","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}