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

{"title":"Surface topography analysis in cold spray additive manufacturing","authors":"Paloma Sirvent ,&nbsp;Ana Lozano ,&nbsp;Miguel A. Garrido-Maneiro ,&nbsp;Pedro Poza ,&nbsp;Rordolpho F. Vaz ,&nbsp;Vicente Albaladejo-Fuentes ,&nbsp;Irene G. Cano","doi":"10.1016/j.precisioneng.2024.12.007","DOIUrl":"10.1016/j.precisioneng.2024.12.007","url":null,"abstract":"<div><div>Additive manufacturing, and particularly the cold spray technology for additive manufacturing (CSAM), is fast becoming a key technology to produce components in an efficient and environmentally friendly manner. This method usually requires a final rectification to generate specific surface topographies. The novelty of this paper is related to the capabilities of the CSAM technique to control the surface topography of the samples. Thus, this work investigates the topography of CSAM samples and its correlation with the processing parameters. Pure Al and Ti samples were manufactured following two different deposition strategies: traditional and metal knitting. This last strategy constitutes a promising alternative for CSAM to obtain near-net-final shape components. The topography was analyzed by confocal microscopy considering the form, waviness, and roughness components. Moreover, the microstructure and mechanical properties of the samples were also investigated in order to assure reliable freestanding CSAM deposits. Results showed that the waviness was controlled by the spraying line spacing, and that the waviness and roughness profiles of the metal knitting samples presented the largest wavelengths regardless the material. The metal knitting method generated samples with higher thickness and porosity than the traditional strategy, while the mechanical properties at the local scale were not varied. The study highlights the CSAM technology potential for controlling the deposit’s surface topography.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 207-218"},"PeriodicalIF":3.5,"publicationDate":"2024-12-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176755","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":"Atomic insight into the speed effect on deformation mechanisms in nano-scratching of monocrystalline iron","authors":"Juan Chen ,&nbsp;Changlin Liu ,&nbsp;Hao Liu ,&nbsp;Bi Zhang ,&nbsp;Suet To","doi":"10.1016/j.precisioneng.2024.12.006","DOIUrl":"10.1016/j.precisioneng.2024.12.006","url":null,"abstract":"<div><div>Ultra-high-speed machining offers significant potential to enhance material removal efficiency and reduce subsurface damage in metals. However, the interplay between machining temperature and speed on dislocation evolution and subsurface damage remains inadequately understood. This study employs molecular dynamics simulations to investigate surface and subsurface deformation mechanisms in iron across various machining speeds. Results indicate that increased machining speed improves material removal efficiency. The high strain zone concentrates near the machined surface and decreases with depth, while higher machining speeds further confine shear strain to a smaller region. Specifically, the decreased dislocation length at high machining speed indicates a deformation mechanism shift dominated by the strain rate effect. Additionally, subsurface damage depth decreases with higher speeds due to reduced shear strain penetration and enhanced stress relaxation. These findings contribute to the development of low-damage machining techniques for iron and other difficult-to-machine metals within a wide speed range.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 219-230"},"PeriodicalIF":3.5,"publicationDate":"2024-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176767","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":"Low-cost and precise magnetorheological fabrication of miniature glass optics","authors":"Xinyu Chen ,&nbsp;ZiHui Zhu ,&nbsp;LiMin Zhu ,&nbsp;Zhiwei Zhu","doi":"10.1016/j.precisioneng.2024.12.005","DOIUrl":"10.1016/j.precisioneng.2024.12.005","url":null,"abstract":"<div><div>This paper presents an innovative magnetorheological (MR) fabrication method for directly generating precision miniature glass optics without the need of precision grinding. In this method, the optimized rotating small ring-shaped permanent-magnet tool (PMT) enhanced the viscosity of the MR slurry with abrasives inside the working gap between the workpiece material and PMT, thereby achieving the non-contact removal of the workpiece materials. Through a combination of theoretical analysis and experimental tests, the PMT with axial magnetization has been selected to generate a high-performance Gaussian-like tool influence function. The effects of the working gap widths, spindle speeds, and dwell time on the material removal behavior were systematically studied through a self-developed three-axis MR fabrication system. Accordingly, a gap width of 0.4 mm and a spindle speed of 800 rpm were recommended to balance the material removal rate and the alignment complexity. By precisely controlling the dwell time, ultra-smooth surfaces with form errors of around 21.538 nm, 101.043 nm, and 396.170 nm (rms) were achieved for fabricating the planar, spherical, and freeform surfaces on flat K9 glasses, respectively. The results demonstrate the effectiveness of the proposed MR fabrication method for the low-cost fabrication of miniature optics with complex shapes.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 179-190"},"PeriodicalIF":3.5,"publicationDate":"2024-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176756","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":"Micro-scale modeling and analysis on material removal mechanisms for flexible ball-end tool polishing incorporating the curvature effect","authors":"Chenchun Shi ,&nbsp;Xiaokang Zhang ,&nbsp;Yicheng Wu ,&nbsp;Jinbang Li ,&nbsp;Wei Wu ,&nbsp;Chi Fai Cheung ,&nbsp;Zhenzhong Wang ,&nbsp;Chunjin Wang","doi":"10.1016/j.precisioneng.2024.12.004","DOIUrl":"10.1016/j.precisioneng.2024.12.004","url":null,"abstract":"<div><div>Optical freeform surfaces (OFS) have been extensively employed as core components in advanced optical systems for their excellent performances. However, the surface complexity and the high surface accuracy do impose challenges to the processing of OFS, especially the surface form maintaining or control during polishing. As one of the promising ultra-precision machining technologies to fabricate OFS, the flexible ball-end tool (FBET) polishing becomes available due to its attractive technical advantages. Nevertheless, there are still lack of more comprehensive insights on material removal mechanisms for FBET polishing incorporating the curvature effect, particularly from a microscopic scale, which is of great significance to determine the surface quality and form control in ultra-precision polishing process. In this paper, different from those published macro-scale Preston law-based models, a micro-scale material removal model is developed based on the mutual interaction of the slurry, polishing pad and curved workpiece among the FBET polishing interfaces with micro-contact theory and tribology theory, wherein various parameters embodied in FBET polishing are formulated quantitatively, such as slurry characteristics, pad properties, tool features, processing conditions, as well as workpiece curvature effect. The FBET is designed and adopted to conduct the spot polishing experiments within the concave curvature radius range from 75 mm to 225 mm, wherein the curvature radius range from 225 mm to 800 mm is theoretically chosen as an extension of this research. The predicted results agree well with the experimentally measured section profiles of polishing spots, thereby demonstrating the correctness and effectiveness of the proposed model. Furthermore, the effective relative velocity <em>U</em> together with the separation gap <em>d</em> between reference plane and workpiece surface are known as the two key parameters to account for the material removal mechanisms, and the latter is figured out to be the sensitive one to the curvature effect rather than the former. Through the analysis of key parameters, the established model is capable of helping to strengthen the understanding of material removal mechanisms for FBET polishing with the consideration of curvature effect, addressing those cannot be interpreted by the classical Preston equation previously, which is meaningful for precision control of material removal during polishing of OFS.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 191-206"},"PeriodicalIF":3.5,"publicationDate":"2024-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176754","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":"Two-point diameter calibration of a sphere by a micro-coordinate measuring machine using a silicon gauge block as a reference standard","authors":"Yohan Kondo ,&nbsp;Akiko Hirai ,&nbsp;Toshiharu Katsube ,&nbsp;Natsumi Kawashima ,&nbsp;Youichi Bitou","doi":"10.1016/j.precisioneng.2024.12.003","DOIUrl":"10.1016/j.precisioneng.2024.12.003","url":null,"abstract":"<div><div>The National Metrology Institute of Japan (NMIJ) developed an accurate two-point diameter measurement system for a sphere by using a micro-coordinate measuring machine (μ-CMM) with a gauge block for calibrating the radius of the μ-CMM probe. The surface roughness of end faces of the gauge block is a key uncertainty factor and, to reduce this in calibrating the μ-CMM probe, a newly fabricated silicon gauge block with a polished surface roughness of a few nanometers or less was used. To overcome poor repeatability caused by interaction forces acting on the probe, we developed a μ-CMM probe with T-shaped sharp styli and an 8-μm tip radius, which minimized the contact area between the stylus tip and gauge block. A calibrated μ-CMM probe (expanded uncertainty of 7.4 nm; <em>k</em> = 2) equipped with the newly developed T-shaped sharp styli was used to measure the mean two-point diameter of a sphere with an expanded uncertainty of 15 nm (<em>k</em> = 2).</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 167-178"},"PeriodicalIF":3.5,"publicationDate":"2024-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176759","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":"Scaling photogrammetry: A comparative evaluation and metrological assessment across small- and meso-scale domains","authors":"Mattia Trombini ,&nbsp;Giacomo Maculotti ,&nbsp;Domenico Augusto Maisano ,&nbsp;Alfonso Pagani ,&nbsp;Fiorenzo Franceschini","doi":"10.1016/j.precisioneng.2024.12.002","DOIUrl":"10.1016/j.precisioneng.2024.12.002","url":null,"abstract":"<div><div>Photogrammetry inspection is a Machine Vision (MV) technique intensely employed to assess the geometry of industrial assets across several measurement scales, ranging from micro-scales focusing on surface to meso- and large-scales targeting geometrical features and shape.</div><div>This research endeavors to conduct a comprehensive comparative evaluation of photogrammetry across different dimensional scale domains, aiming to establish a framework for assessing performance levels in various aspects, driven by the portability of the instrumentation, measurement performance and proficiency. Central to the current methodology is employing a single camera, driven by the research's forward-looking goal to integrate drone technology equipped with a solitary camera as the primary payload. In addition, this work presents a statistical quantitative investigation where the most relevant sources of uncertainty are taken into account. Three case studies about a small truss, a ball-bar, and a collaborative robot accompany the analysis.</div><div>Finally, this study proposes a framework for assessing the expanded uncertainty and the relative uncertainty across the scales, revealing that the latter decreases with larger measurand, providing a value of 0.2 % when dealing with meso-scale objects.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 124-140"},"PeriodicalIF":3.5,"publicationDate":"2024-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176762","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":"A Fast flatness deviation evaluation algorithm for point cloud data","authors":"Fan Liu ,&nbsp;Yanlong Cao ,&nbsp;Tukun Li ,&nbsp;Jiangxin Yang ,&nbsp;Junnan Zhi ,&nbsp;Jia Luo ,&nbsp;Yuanping Xu ,&nbsp;Xiangqian Jiang","doi":"10.1016/j.precisioneng.2024.11.013","DOIUrl":"10.1016/j.precisioneng.2024.11.013","url":null,"abstract":"<div><div>This paper proposes and develops a novel method, namely the Partially Iterative Algorithm (PIA), for high-speed assessment of flatness deviation for point cloud data, which is typically measured data obtained by advanced instruments for precision manufacturing, such as optical scanners and industrial computed tomography. Firstly, an enhanced flatness deviation model is established based on the minimum zone principle, which is strictly adhered to the latest ISO definition. Secondly, the proposed method is detailed, including the Dynamic Point Set (DPS), the update scheme, and the terminal condition. Thirdly, comparisons are conducted with typical methods for flatness deviation assessment, along with a practicability test via the simulated dataset and measuring dataset. The results show that the proposed method can accurately and rapidly assess flatness deviation on point cloud data with massive measuring points.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 90-100"},"PeriodicalIF":3.5,"publicationDate":"2024-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176761","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":"Overall improvement of macro electrochemical jet milling by utilizing a novel cathode tool with an ultra narrow inter-electrode gap","authors":"Junzhong Zhang,&nbsp;Zhihao Shen,&nbsp;Ningsong Qu","doi":"10.1016/j.precisioneng.2024.12.001","DOIUrl":"10.1016/j.precisioneng.2024.12.001","url":null,"abstract":"<div><div>Electrochemical jet milling (EJM) offers significant benefits for producing workpieces, showcasing various advantages in terms of quality and design flexibility. However, macro-scale EJM currently encounters limitations regarding machining efficiency and surface precision. A critical determinant of these aspects is the inter-electrode gap (IEG), with its optimization presenting an opportunity to enhance both precision and efficiency. Reducing the IEG is particularly desirable as it promises considerable improvements in machining efficiency and surface quality. Nonetheless, achieving a narrower IEG is challenging due to the risk of sparking from excessively high current densities at the cathode tool tips. To address this issue, this study introduces an innovative cathode tool design tailored to exploit the characteristics of electric in EJM. This design strategically removes the energy concentration area. As a result, this advancement allows for an ultra-narrow IEG of 0.05 mm, setting a new benchmark for the narrowest IEG achievable in macro EJM. Employing this novel cathode tool leads to a substantial leap in machining performance at an IEG of 0.05 mm. When compared with the conventional machining gap of 0.2 mm, the refined 0.05 mm IEG not only boosts the material removal rate by an impressive 107 % but also enhances surface quality. Specifically, the experimental results showed that the minimum surface roughness produced by the RD cathode tool was reduced by nearly 86.2 % than that of the surface produced by the standard cathode tool. Moreover, the overcut area was reduced by nearly 60.1 %, and stray corrosion was eliminated.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 111-123"},"PeriodicalIF":3.5,"publicationDate":"2024-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176760","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 data driven formulation for predicting jetting states and printing zone of high-viscosity nanosilver ink in inkjet-based 3D printing","authors":"Muhammad Ahsan Saleem ,&nbsp;Xingzhi Xiao ,&nbsp;Saqib Mamoon ,&nbsp;Gang Li ,&nbsp;Tingting Liu","doi":"10.1016/j.precisioneng.2024.11.012","DOIUrl":"10.1016/j.precisioneng.2024.11.012","url":null,"abstract":"<div><div>Inkjet printing offers significant benefits for additive manufacturing (AM) and printed electronics, such as cost-effectiveness, scalability, non-contact printing, and the flexibility for ad-hoc customization. However, some challenges such as stable jetting states and defined printing zone still needs attention. Data driven modeling such as machine/deep learning (ML/DL) as a predictive methodology has proven to reduce the experimental cost and workload in AM for low-viscosity inks. However, there is an oversight in ML extension to high-viscosity inks due to some inherit challenges such as irregular shape formation, and adhesiveness. Therefore, this study is focused on the prediction of jetting states and defining the printing zone for three-dimensional (3D) inkjet printing of high-viscosity ink. The experimental data is comprised of equipment parameter settings, material properties, and camera-captured features. The jetting behavior is recorded with a high-speed camera and carefully categorized into five classes: <em>no jetting, orifice adhesion, droplet jetting, orifice tail</em>, and <em>beads hanging</em>. A robust and efficient high-viscosity 3D printing U-Net (HV3DP-UNet) model is proposed, that achieved the jetting state and printing zone prediction accuracy of 97.98% and 100% respectively. For the fair comparison, three traditional ML and two more DL models are tested and analyzed in detail. The robustness and efficacy of the proposed model is supplemented with four performance metrics, i.e., accuracy, precision, recall and f1-score. The models’ efficacy has been proved by achieving improved results on the public dataset, the proposed model has achieved overall prediction accuracy of 92.95%. The presented data-driven approach serves as a systematic framework for enhancing quality of inkjet-based 3D printing utilizing high-viscosity ink.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 63-76"},"PeriodicalIF":3.5,"publicationDate":"2024-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176194","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":"Advances in hot embossing technology for optical glass micro-nanostructures: A review","authors":"Tao Zhu ,&nbsp;Kangsen Li ,&nbsp;Feng Gong","doi":"10.1016/j.precisioneng.2024.11.016","DOIUrl":"10.1016/j.precisioneng.2024.11.016","url":null,"abstract":"<div><div>Hot embossing forming technology is a key technology for fabricating micro-nanostructures on optical glass, providing a process for efficient, large-scale, and economical production of optical glass components with excellent optical performance. The process uses coated mold with micro-nanostructures to hot emboss optical glass at high temperatures. However, the intricate and unpredictable flow and deformation behavior of viscoelastic glass in the thermodynamic field presents challenges to researchers. Therefore, this paper begins with an evaluative review of the adhesion and friction effects of glass on different mold and coating materials. Based on this foundation, the paper comprehensively summarizes both theoretical and applied advanced studies on the filling and flow deformation mechanisms of viscoelastic glass during molding and the quality of the final molded product. Then, the development of high-precision prediction models and molding parameter control systems is proposed for the future establishment of an integrated study framework that can predict glass flow deformation and to facilitate the efficient filling and accurate replication of micro-nanostructures. Finally, after summarizing the current research of the hot-rolled embossing for optical polymer, this paper pioneeringly proposes the unresolved critical challenges and related solutions of hot-rolled embossing for optical glass, setting the course for future research efforts in the emerging field of advanced hot-rolled embossing technologies.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 141-166"},"PeriodicalIF":3.5,"publicationDate":"2024-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176765","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}