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

{"title":"Sensor-integrated data acquisition and machine learning implementation for process control and defect detection in wire arc-based metal additive manufacturing","authors":"Gaurav Kishor,&nbsp;Krishna Kishore Mugada,&nbsp;Raju Prasad Mahto","doi":"10.1016/j.precisioneng.2025.04.028","DOIUrl":"10.1016/j.precisioneng.2025.04.028","url":null,"abstract":"<div><div>Wire Arc Additive Manufacturing (WAAM) offers significant advantages, such as a high deposition rate and cost-effectiveness compared to conventional manufacturing methods. However, WAAM faces challenges related to porosity, cracking, inclusions, lack of fusion, and geometric inaccuracies, which degrade component quality and performance. To optimize the quality of the built parts and minimize the potential defects, a good approach is to use sensors-based monitoring and controlling the process. In the process the date can be recorded by using sensors and send real-time feedback to the control system. This study aims to provide a comprehensive review of in-process sensing technologies and their integration with control systems to mitigate these defects. This work systematically categorizes sensing approaches including optical, acoustic, visual, thermal, and multi-signal methods while emphasizing the role of machine learning in real-time data processing for defect detection and control. Effectively detecting different types of defects usually requires various sensing technologies, specific focus areas, and careful attention. This also involves real-time data integration and advanced data processing. A key novelty of this review lies in its critical evaluation of multi-sensor integration strategies, real-time data fusion techniques, and their potential to enhance WAAM process reliability. By addressing the fundamental principles, current limitations, and future research directions, this study serves as a valuable resource for advancing intelligent monitoring solutions in WAAM.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 163-187"},"PeriodicalIF":3.5,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143883084","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":"Dynamic characteristics of a high-speed air-bearing spindle and their effects on surface generation in ultra-precision machining","authors":"Tongke Liu ,&nbsp;Pan Guo ,&nbsp;Zengwen Dong ,&nbsp;Zhiwen Xiong ,&nbsp;Donglei Liu ,&nbsp;Shaojian Zhang ,&nbsp;Mingyu Liu","doi":"10.1016/j.precisioneng.2025.04.022","DOIUrl":"10.1016/j.precisioneng.2025.04.022","url":null,"abstract":"<div><div>In ultra-precision machining, a high-speed air-bearing spindle (HS-ABS) is a key component with high rotational accuracy, which can machine high-quality surfaces with nanometric surface roughness and sub-micrometric form error. The dynamic characteristics of the HS-ABS play a crucial role in affecting the machined surface quality. However, there is still a research gap on the dynamic characteristics of an HS-ABS under multiple degrees of freedom, especially about the effects on surface generation in ultra-precision diamond milling (UPDM). In this paper, a nonlinear dynamic model was first developed to clarify the dynamic characteristics of the HS-ABS under five degrees of freedom with three translations and two tilting motions. Second, a surface generation model was proposed to study the surface topographies formed under the dynamic characteristics of the HS-ABS. A series of cutting experiments were conducted to examine the cutting forces and surface topographies. The theoretical and experimental results show that the dynamic characteristics of the HS-ABS have: (1) an axial natural frequency with small nonlinear variation, producing regular straight patterns with slight deformation at the machined surface; (2) a radial natural frequency with significant nonlinear variation, forming regular diagonal patterns with remarkable deformation, and minor chaos generating slight random fluctuation; (3) twin tilting natural frequencies with significant nonlinear variation, causing regular diagonal or straight patterns with remarkable deformation and inevitable chaos generating apparent random fluctuation, even deflection. This study provides a comprehensive understanding of the dynamic characteristics of the HS-ABS and the surface formation mechanisms under the HS-ABS's dynamic characteristics in ultra-precision machining.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 215-237"},"PeriodicalIF":3.5,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891074","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":"Smooth trajectory generation and hybrid B-splines-quaternions based tool path interpolation for a 3T1R parallel kinematic milling robot","authors":"Sina Akhbari ,&nbsp;Mehran Mahboubkhah","doi":"10.1016/j.precisioneng.2025.04.020","DOIUrl":"10.1016/j.precisioneng.2025.04.020","url":null,"abstract":"<div><div>This paper presents a smooth trajectory generation method for a four-degree-of-freedom parallel kinematic milling robot. The proposed approach integrates B-spline and Quaternion interpolation techniques to manage decoupled position and orientation data points. The synchronization of orientation and arc-length-parameterized position data is achieved through the fitting of smooth piece-wise Bezier curves, which describe the non-linear relationship between path length and tool orientation, solved via sequential quadratic programming. By leveraging the convex hull properties of Bezier curves, the method ensures spatial and temporal separation constraints for multi-agent trajectory generation. Unit quaternions are employed for orientation interpolation, providing a robust and efficient representation that avoids gimbal lock and facilitates smooth, continuous rotation. Modifier polynomials are used for position interpolation. Temporal trajectories are optimized using minimum jerk, time-optimal piece-wise Bezier curves in two stages: task space followed by joint space, implemented on a low-cost microcontroller. Experimental results demonstrate that the proposed method offers enhanced accuracy, reduced velocity fluctuations, and computational efficiency compared to conventional interpolation methods.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 117-135"},"PeriodicalIF":3.5,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143864137","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 sensitivity analysis method for geometric errors in precision lathes based on variance decomposition and partial derivative integration","authors":"Xuetao Qiao ,&nbsp;Yibo Wang ,&nbsp;Kai Cheng ,&nbsp;Hang Xu ,&nbsp;Cunfu Yan","doi":"10.1016/j.precisioneng.2025.04.004","DOIUrl":"10.1016/j.precisioneng.2025.04.004","url":null,"abstract":"<div><div>Precision machine tools are influenced by geometric errors during the machining process, making the accurate identification of key geometric error terms essential for effective workpiece compensation and improved machining accuracy. However, current sensitivity analysis methods often overlook the interactions between high-order error terms, leading to inadequate efficiency and accuracy in error compensation. To address this issue, this paper proposes the VPM sensitivity analysis method, which is based on variance decomposition and partial derivative integration, considering the coupling effects of high-order geometric error terms. First, the volumetric error model of the tool-workpiece system in precision lathes was established using multi-body system theory and homogeneous coordinate transformation. Then, the VPM sensitivity analysis method was introduced, and a new sensitivity index <em>N</em>_<em>i</em> was defined. Based on the volumetric error model, Sobol and VPM sensitivity analysis were performed in different directions. Taking a cylindrical workpiece as an example, a turning test was carried out on a precision lathe. The results demonstrate that, compared to the traditional Sobol sensitivity analysis method, the proposed VPM sensitivity analysis method achieves superior convergence accuracy and enhances the roundness of the workpiece by 36.7 %, thus verifying the effectiveness of the method.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 203-214"},"PeriodicalIF":3.5,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891073","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":"Modeling of material removal in pre-structured magnetorheological elastic polishing based on lame differential equation and its experimental validation","authors":"Chongqiu Zhou ,&nbsp;Ting Liu ,&nbsp;Xinsheng He ,&nbsp;Chengwu Wang","doi":"10.1016/j.precisioneng.2025.04.024","DOIUrl":"10.1016/j.precisioneng.2025.04.024","url":null,"abstract":"<div><div>Magnetorheological elastic polishing is a new polishing method for aluminum alloy mirrors due to its high polishing efficiency and low processing damage. However, the traditional polishing pressure model is not applicable to magnetorheological elasticity polishing processing conditions due to the lack of supporting removal theory. As a result, the processing can only rely on experience, often leading to the problem of uneven polishing. In order to achieve the MREP process improvement and enhance the polishing of aluminum alloys, a pre-structured magnetorheological elastic polishing (MREP) removal method is proposed. In this study, the gradient magnetic field excited by permanent magnets was calculated based on the molecular current model. The interaction between magnetized particles in the magnetic chain inside the magnetorheological elastic polishing head was analyzed by using the magnetic dipole model, and the elastic modulus E was constructed as a function of the gradient magnetic field. Using the idea of finite elements, the machining pressure of MREPH was solved according to Hooke's law and lame differential equation. A mathematical model of the material removal function of MREPH was developed by combining Preston's equation. To verify the accuracy of the contact pressure model, the contact pressure was measured by using vision sensors and pressure sensors. The accuracy of the established material removal model was verified by polishing experiments. Fixed-point polishing and single trajectory polishing were experimented. Moreover, the relationships between the polishing effects and the process parameters (Polishing speed, extrusion depth, and polishing magnetic field strength) were investigated. According to the generated material removal map and above impact relationship, process optimization can be carried out. Finally the excellent surface quality was obtained. Sa decreased from 187.368 nm to 20.385 nm (Optimized by 89.1 %). Sz decreased from 1372.539 nm to 164.441 nm (Optimized by 88.0 %). Ra decreased from 245.109 nm to 25.835 nm (Optimized by 89.4 %). PV decreased from 714.921 nm to 85.163 nm (Optimized by 88.1 %).</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 99-116"},"PeriodicalIF":3.5,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143864140","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":"Study on photocatalysis/vibration-assisted finishing for deterministic polishing","authors":"Zhichao Geng,&nbsp;Ning Huang,&nbsp;Marco Castelli,&nbsp;Fengzhou Fang","doi":"10.1016/j.precisioneng.2025.04.025","DOIUrl":"10.1016/j.precisioneng.2025.04.025","url":null,"abstract":"<div><div>Reaction-sintered silicon carbide (RS-SiC) is a promising material for optical systems like space telescopes due to its superior mechanical and thermal properties. However, its multiphase composition, high hardness, and chemical inertness pose significant challenges for conventional polishing techniques in achieving both low form error and surface roughness while maintaining processing efficiency. Photocatalytic/vibration-assisted finishing is a high-efficiency and high-precision polishing process for RS-SiC. After studying the influencing factors and stability of the tool influence function, this study extends the photocatalytic/vibration-assisted finishing to deterministic polishing. The matrix method utilizing the Lucy-Richardson algorithm was employed to obtain dwell time distribution efficiently. The fluctuating concentric circular tool path is developed to avoid periodic residues, interpolation errors, and frequent \"swerves\". Based on the above innovations, RS-SiC workpieces are deterministically polished to achieve Gaussian hollow topography with a roughness of 0.33 nm in Ra, 0.42 nm in RMS, and a form error of ±30 nm in PV. This study provides a novel approach to the deterministic polishing of RS-SiC.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 52-58"},"PeriodicalIF":3.5,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143854441","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":"Rapid stabilization of high-speed motion stage positioning oscillation using a vibration reduction unit","authors":"Lanyu Zhang,&nbsp;Shaoxuan Zhang,&nbsp;Jian Gao,&nbsp;Peiyuan Zhang,&nbsp;Fuyuan Feng,&nbsp;Yuheng Luo,&nbsp;Yachao Liu","doi":"10.1016/j.precisioneng.2025.04.015","DOIUrl":"10.1016/j.precisioneng.2025.04.015","url":null,"abstract":"<div><div>A high-speed motion stage with less settling time is essential for most microelectronics manufacturing equipment. Usually, high-speed motion induces overshoot and inertial vibration during the stage positioning process. To rapidly reduce the stage positioning oscillation, this paper proposes a novel vibration-reduction-unit (VRU) for speeding up the positioning stabilization of the stage. More precisely, the VRU includes a servo actuator, and it is installed on the fixed-end of the stage with maintaining a small-gap from the displacement output-end of the stage. During the deceleration positioning process of the stage, the VRU is actuated with optimal start-up condition to actively act on the stage with an acting force and interfere the stage inertial vibration. This start-up condition including the acting moment of the VRU is determined based on the in-time displacement. The theoretical relationship between the VRU acting force and the attenuation of the stage inertial vibration amplitude is clarified based on the dynamics and force analyses. The effects of different VRU acting forces on stage vibration reduction are examined through simulations. A series of experiments are conducted, and the results show that the proposed VRU can help the stage to significantly reduce the vibration amplitude and settle down rapidly.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 89-98"},"PeriodicalIF":3.5,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143854981","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":"Sequential identification of joint-dependent geometric errors for industrial robots using a laser tracker","authors":"Hanqian Wu ,&nbsp;Nuodi Huang ,&nbsp;Jiangheng Pi ,&nbsp;Xu Zhang ,&nbsp;Limin Zhu","doi":"10.1016/j.precisioneng.2025.04.014","DOIUrl":"10.1016/j.precisioneng.2025.04.014","url":null,"abstract":"<div><div>Industrial robots are vital in modern industrial automation, yet limited absolute positioning accuracy constrains their broader applications in precision manufacturing. To improve both absolute positioning accuracy and task reliability, robot error identification and compensation are essential steps. This study investigates the calibration of joint-dependent geometric errors to enhance the absolute positioning accuracy of industrial robots. The robotic kinematic model considering the 36 joint-dependent geometric errors is firstly modeled. Based on this model, an innovative approach is proposed to isolate and sequentially identify joint-dependent geometric errors through joint-wise motion data. By systematically separating and quantifying these errors, the method allows for precise identification and compensation of joint-dependent geometric errors, thereby enhancing the absolute positioning accuracy of the robot. Experimental results show that the proposed method can substantially improve the absolute positioning accuracy of industrial robots. The proposed model accounts for approximately 78 % of absolute positioning errors, outperforming the classical DH model by 17 %, thereby demonstrating its superior effectiveness in controlling absolute positioning errors.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 1-9"},"PeriodicalIF":3.5,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143843310","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":"Feedback switching adaptive control for trajectory tracking in walking piezoelectric actuator","authors":"Zhiwei Ruan,&nbsp;Qin Li,&nbsp;Liang Guo,&nbsp;Chenyang Ding","doi":"10.1016/j.precisioneng.2025.04.018","DOIUrl":"10.1016/j.precisioneng.2025.04.018","url":null,"abstract":"<div><div>The nonlinear characteristics and continuous foot switching in Walking Piezoelectric Actuator (WPA) necessitate an applicable control scheme for practical application. This paper proposes a Feedback Switching Adaptive Control (FSAC) based on Adaptive Proportional-Integral-Derivative (APID) and aligned with the WPA driving principles for trajectory tracking control. A Quantum Particle Swarm Optimization-based Neural Network (QPSNN) is employed for online tuning of APID control gains. The APID based on QPSNN eliminates the need to model nonlinearity and foot switching, dynamically adjusts control parameters in real time. The FSAC incorporates WPA driving principles with APID to enable precise tracking control under foot-switching conditions. The stability of the proposed APID is theoretically analyzed using a Lyapunov framework. Comparative experiments under different trajectories and varying loads were conducted on the self-designed WPA stage. The proposed FSAC is verified the superior tracking performance and strong variable load adaptability in experiment.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 10-23"},"PeriodicalIF":3.5,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143848268","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":"Analysis of diffusion in Fe/4H-SiC by molecular dynamics method","authors":"Yuxiang Huang ,&nbsp;Hui Huang ,&nbsp;Xipeng Xu ,&nbsp;Min Wu ,&nbsp;Yiqing Yu ,&nbsp;Nian Duan","doi":"10.1016/j.precisioneng.2025.04.016","DOIUrl":"10.1016/j.precisioneng.2025.04.016","url":null,"abstract":"<div><div>Silicon carbide(SiC) is a hot topic in current semiconductor material research and is widely used but typically difficult to process. It was found that the interface reaction between the metal Fe and single crystal SiC contributes to the removal of single crystal SiC materials. The diffusion between the atoms of Fe and SiC is the basis of solid state mass transfer and reaction. In this paper, a series of static diffusion simulations of metal iron and SiC at different temperatures by molecular dynamics (MD) method are conducted to elucidate the mechanism of static diffusion in Fe/4H-SiC. It was found that the diffusion temperature range of iron (Fe) on the carbon face of 4H-SiC is similar to experimental results, and the thickness of the diffusion layer increases with temperature, consistent with experimental observations, verifying the accuracy of the simulation model. Based on that, a series of frictional diffusion simulations of metal iron and SiC at different speeds are carried out to elucidate the mechanism of frictional diffusion in Fe/4H-SiC. The study also indicated that frictional diffusion can occur at temperatures much lower than free interface diffusion. The friction speed has a significant impact on diffusion behavior, mainly manifested in the significantly different diffusion characteristics of carbon surfaces at different speeds. In addition, the increase in friction speed makes the diffusion zone more pronounced.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 286-297"},"PeriodicalIF":3.5,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143922092","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}