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

{"title":"Real-time holographic imaging programmable metasurfaces based on hardware accelerator computation","authors":"Haoliang Cheng ,&nbsp;Yunyun Yang ,&nbsp;Manna Gu ,&nbsp;Ying Tian ,&nbsp;Bo Fang ,&nbsp;Chenxia Li ,&nbsp;Zhi Hong ,&nbsp;Xufeng Jing","doi":"10.1016/j.precisioneng.2025.05.004","DOIUrl":"10.1016/j.precisioneng.2025.05.004","url":null,"abstract":"<div><div>—Dynamic control of electromagnetic waves can be achieved using programmable metasurfaces. We propose a 1-bit real-time holographic programmable metasurface based on hardware acceleration. The field-programmable gate array (FPGA) is used as the hardware accelerator to accelerate the computation of the backpropagation algorithm, obtaining the encoding pattern of the programmable metasurface unit structure. By controlling the on/off state of diodes, we encode the programmable metasurface and achieve real-time hologram calculation at a rate of 13 frames per second. The proposed programmable metasurface can achieve a phase variation of 180° in its unit structure. Furthermore, we experimentally fabricated and tested the designed programmable metasurface using near-field scanning. When the incident electromagnetic wave frequency was 7.66 GHz, the programmable metasurface successfully realized real-time holographic imaging function, with theoretical and experimental results being consistent.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 495-504"},"PeriodicalIF":3.5,"publicationDate":"2025-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144124095","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":"Influence of air cushion throttling structure on support performance of grinding machine based on CFD","authors":"Jiahui Xu ,&nbsp;Xianglong Zhu ,&nbsp;Renke Kang ,&nbsp;Hailong Cui ,&nbsp;Zhigang Dong","doi":"10.1016/j.precisioneng.2025.05.010","DOIUrl":"10.1016/j.precisioneng.2025.05.010","url":null,"abstract":"<div><div>As a critical component in the transition of production processes, the support stability of the transport system in the high-end grinding machines significantly impacts the surface quality of the wafer. To guarantee the stability of the transposition system under heavy loads and large floating volumes, an air cushion structure supported by aerostatic pressure with slender holes is proposed. Based on Computational Fluid Dynamics (CFD), the effects of traditional orifices, slender orifices, cylindrical cavity, and square cavity throttling on the air cushion pressure distribution and flow field characteristics were analyzed, determining the superior performance of the slender orifice structure. Furthermore, the influence of structural factors, including throttling hole diameter, number and length-diameter ratio, on air cushion performance and floating displacement is discussed. The findings indicate that, at a film thickness of 34 μm, the slender hole exhibits a bearing capacity 7.28 times higher than that of the small hole, accompanied by a stiffness that is 3.28 times increased. Moreover, for slender holes, a positive correlation is observed between the load capacity and both the diameter and the number of throttling holes, while stiffness is negatively correlated with these parameters. The length-diameter ratio has a negligible influence on both load capacity and stiffness. Building on the above findings, a ceramic-supported air cushion with an orifice diameter of 1 mm was fabricated, and floating displacement measurements were conducted. Under a load of approximately 1000 kg, the air cushion lift exceeded 20 μm, thereby validating its supporting performance. The maximum error compared to the calculated results was less than 5.96 %. The results of the research offer both theoretical underpinning and data evidence for designing air cushions with high bearing capacity and stiffness under conditions of large floating volumes.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 409-422"},"PeriodicalIF":3.5,"publicationDate":"2025-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144072667","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":"Review and prospect of precision machining of bearing rollers: Cylindrical, tapered and spherical rollers","authors":"Yongquan Sun ,&nbsp;Guang Chen ,&nbsp;Shuai Wang ,&nbsp;Chunlei He ,&nbsp;Yongxiang Su ,&nbsp;Changxu Wei ,&nbsp;Qian Gao ,&nbsp;Chengzu Ren","doi":"10.1016/j.precisioneng.2025.05.009","DOIUrl":"10.1016/j.precisioneng.2025.05.009","url":null,"abstract":"<div><div>Rolling bearings are the most widely used basic components in the industrial field, and their rotational accuracy, ultimate speed and fatigue life significantly affect the performance and reliability of the assembled equipment. As a pivotal element in bearings, the precision machining quality of rollers affects the performance of bearings. In this work, a comprehensive summary of precision machining techniques for cylindrical rollers, tapered rollers, and spherical rollers is provided, and prospects for different machining methods are discussed. Firstly, the influence of roller precision requirements, namely shape accuracy, batch consistency and surface quality, on bearing performance is discussed. Subsequently, the ultra-precision machining and surface finishing of cylindrical rollers, tapered rollers, and spherical rollers are reviewed respectively, comparing the roundness error, batch diameter variation, and surface roughness obtained by different machining methods. Ultra-precision machining processes such as centerless grinding and double-discs lapping can effectively improve the geometric accuracy of rollers, while finishing machining processes such as superfinishing and shear thickening polishing can significantly promote the surface quality of rollers. Furthermore, in view of the above advanced methods, the future development trend of precision machining of bearing rollers is discussed.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 436-467"},"PeriodicalIF":3.5,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144099161","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":"Investigation on machinability and sustainability aspects during hard turning under GO nanofluid MQL environment for precision and cleaner manufacturing","authors":"Saswat Khatai,&nbsp;Ashok Kumar Sahoo,&nbsp;Ramanuj Kumar,&nbsp;Amlana Panda","doi":"10.1016/j.precisioneng.2025.05.006","DOIUrl":"10.1016/j.precisioneng.2025.05.006","url":null,"abstract":"<div><div>The current study involves the analysis of machinability and sustainability metrics during hard turning through Taguchi L₂₇ OA design of experiment under GO nano-cutting fluid MQL environment by low cost CVD coated carbide tools. This study examines machinability and sustainability factors, including flank wear, surface integrity, cutting temperature, power consumption, carbon emissions, and noise emissions, during hard machining operations. GO nano-cutting fluid provides superior cooling and lubrication facility at the cutting zone, resulting in lowest cutting temperatures of 55.2 °C and cutting noise levels of 69.3 dB throughout the investigation. At a parametric combination of d (0.1 mm), f (0.05 mm), and v (200 m/min), the lowest surface roughness was detected, exhibiting minimal surface defects with high precision as the lowest circularity and cylindricity error obtained at this run. Feed (57.30 %) and depth of cut (49.51 %) significantly affect carbon emissions and noise emissions, respectively. Cutting speed is the primary factor influencing flank wear and temperature, with a contribution rate of 61.69 % and 47.50 %, respectively. Feed greatly influences surface roughness with a contribution rate of 44.95 %, whereas depth of cut predominantly affects cutting power with a contribution rate of 51.92 %. The multi-response optimization implementing WASPAS, followed by the entropy method, yields an optimal parametric combination of d (0.1 mm), f (0.05 mm), and v (80 m/min) within the examined range for the most favorable solution considering both machinability and sustainability.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 379-408"},"PeriodicalIF":3.5,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071510","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":"Global optimization of sensor installation angles for separating spindle error and roundness","authors":"Weimin Kang ,&nbsp;Chong Chen ,&nbsp;Liuzhou Zhong ,&nbsp;Jiahao Ruan ,&nbsp;Jianzhong Fu","doi":"10.1016/j.precisioneng.2025.05.007","DOIUrl":"10.1016/j.precisioneng.2025.05.007","url":null,"abstract":"<div><div>Measuring the motorized spindle's motion error and the rotating parts' roundness are of great significance in machining. However, these two errors are usually mixed in measurement, and separating them is a big challenge. The three-probe method is suitable for on-machine measurement because it does not require the movement of the sensor during measurement. However, there is the problem of harmonic suppression in the three-probe method and harmonic suppression is closely related to the sensor installation angle. This study studied the harmonic suppression phenomenon and gave two performance indicators for angle optimization, optimized the angles in global scope, and gave the best recommended values for the sensor installation angles. A special fixture was designed for precise angle measurement and adjustment, and a cross-correlation analysis method was adopted. Simulations were then created to simulate theoretical errors, rounding errors, and angular uncertainties. Finally, experiments were conducted to verify the discussed errors and results.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 364-378"},"PeriodicalIF":3.5,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071509","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 the eco-friendly chemical mechanical polishing of nickel–phosphorus alloy","authors":"Zebin Xia,&nbsp;Peng Lyu,&nbsp;Ze Liu,&nbsp;Jiyu Pan,&nbsp;Fengzhou Fang","doi":"10.1016/j.precisioneng.2025.05.008","DOIUrl":"10.1016/j.precisioneng.2025.05.008","url":null,"abstract":"<div><div>Cutting marks on nickel–phosphorus (NiP) coating surfaces can cause diffraction and stray light, negatively affecting the quality of the workpiece. Drawing on the chemical mechanical polishing mechanism, malic acid, an environmentally friendly organic acid, is used to prepare the polishing solution instead of a strong acid. Then, the optimal formulation of the polishing solution is identified to effectively remove the cutting marks. Using the proposed environmentally friendly polishing solution with the optimal formulation, the NiP coating surface is polished to obtain a surface roughness below 0.3 nm in Sa. Analysis using X-ray photoelectron spectroscopy indicates that H₂O₂ oxidizes the NiP coating surfaces, while malic acid maintains the acidity of the solution and enhances polishing efficiency. Orthogonal experiments are conducted to optimize the polishing parameters, resulting in a surface roughness of 0.26 nm (Sa) on the NiP coating.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 423-435"},"PeriodicalIF":3.5,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144089517","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":"Toolpath smoothing and motion planning for the diamond turning of microlens arrays with improved uniformity","authors":"Yangqin Yu,&nbsp;Zhiyue Wang,&nbsp;Shaozhi Zhang,&nbsp;Mingjun Ren,&nbsp;Limin Zhu,&nbsp;Xinquan Zhang","doi":"10.1016/j.precisioneng.2025.05.005","DOIUrl":"10.1016/j.precisioneng.2025.05.005","url":null,"abstract":"<div><div>Microlens arrays fabricated by ultra-precision machining commonly suffer from surface nonuniformity, which results in the inconsistency and degradation of their optical performances. One major possible cause is the uneven distribution of toolpath kinematic characteristics, especially the excessive local acceleration and jerk values concentrated at lens edges. To address the issue, this study proposes an optimization strategy comprising toolpath smoothing and motion planning. The toolpath directly generated using equal-angle discretization is first processed by spline interpolation-based smoothing to eliminate the abrupt turnings at lens edges. The smoothed toolpath is then optimized by a replanning process which adaptively adjusts the cutter location point (CLP) density according to local curvature. Lastly, the replanned toolpath and CLPs are further finely tuned by genetic algorithm in which acceleration and jerk feedbacks are integrated using penalty terms. Theoretical analysis demonstrates greatly reduced acceleration and jerk peak values by over 90 % compared to equal-angle discretization. Significantly improved surface uniformity, both among differently located lenses and within a single lens, is verified by experimental investigation. These findings provide a potential solution to the nonuniformity of machined microstructured surfaces, enabling the advanced and consistent performances of optical systems.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 350-363"},"PeriodicalIF":3.5,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144069589","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":"In-process identification of feed drive dynamics considering machining forces","authors":"J.D. McPherson,&nbsp;M. Mehrabi,&nbsp;K. Ahmadi","doi":"10.1016/j.precisioneng.2025.04.027","DOIUrl":"10.1016/j.precisioneng.2025.04.027","url":null,"abstract":"<div><div>This paper presents a new closed-loop dynamics model for ballscrew feed drives in CNC machine tools, enabling non-intrusive, in-process model calibration and motion prediction even in the presence of unmeasured machining forces. The presented model employs a Partially Linear Auto-Regressive with Exogenous input (PL-ARX) structure, where the linear component captures the servo drive and rigid-body dynamics, and the nonlinear component represents unknown machining forces. Kernel-based regression is then used to simultaneously identify the linear dynamics and machining force disturbances from internal controller signals during milling.</div><div>The model is validated on two different CNC machines under experimental milling conditions. Results confirm the approach accurately identifies unbiased linear dynamics despite unmeasured disturbances and achieves precise online motion prediction. These capabilities are critical for enabling real-time feedrate optimization and model-predictive control in advanced machining systems.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 468-483"},"PeriodicalIF":3.5,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144099160","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 an optimized smart tool holder using symmetrical structure for three-axis cutting force measurement in diamond cutting","authors":"Zhongwei Li,&nbsp;Liang An,&nbsp;Huanbin Lin,&nbsp;Yuan-Liu Chen","doi":"10.1016/j.precisioneng.2025.05.002","DOIUrl":"10.1016/j.precisioneng.2025.05.002","url":null,"abstract":"<div><div>Cutting force measurement is an important technique for monitoring the machining process in diamond cutting. This paper presents an optimized smart tool holder using the symmetrical structure of a fast tool servo (FTS) for three-axis cutting force measurement by utilizing six piezoelectric force sensors. The cutting force along each axis was measured by using the differential result of two sensors to eliminate the influence from environmental noise, bias current of charge amplifier, and temperature drift on the measured forces. The symmetrical structure of the tool holder was designed based on a flexible hinge, and the theoretical model was constructed and optimized for high stiffness and low coupling. An improved algorithm combining differential and dynamic accumulation method was developed for stable and accurate static force measurement. Tests were carried out to verify the effectiveness of the algorithm in improving the stability and accuracy of output voltage and static force measurement. The results demonstrated that the influence from environmental noise, bias current, and temperature drift on measured force could be effectively reduced. Subsequently, the smart tool holder was integrated on an FTS for cutting experiments. Compared with a commercial dynamometer, the proposed tool holder system was verified to have excellent performance of high sensitivity and high accuracy in three-axis cutting force measurement, and have capacity of identification of nanometric scale microdefects.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 505-514"},"PeriodicalIF":3.5,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144124096","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":"Topology optimization of a dual-axial piezo-actuated fast tool servo with decoupled kinematics","authors":"Dongpo Zhao ,&nbsp;Benliang Zhu ,&nbsp;Hanheng Du ,&nbsp;Zhichao Shi ,&nbsp;Zhiwei Zhu","doi":"10.1016/j.precisioneng.2025.04.023","DOIUrl":"10.1016/j.precisioneng.2025.04.023","url":null,"abstract":"<div><div>This paper presents the design and development of a novel dual-axial piezo-actuated fast tool servo (FTS) based on a four-node finite element topology optimization design method for application in diamond machining of micro/nano-structured functional surfaces. Utilizing a solid isotropic material with penalization (SIMP) approach to express and analyze topological structure, a design model for multi-performance coupling dynamic optimization was developed. This model defines the natural frequency as the objective function, with constraints on in-plane motion coupling between the input and output ports, input–output compliance, stress, and other performance indicators. By solving the optimal design variables with the method of moving asymptotes (MMA) algorithm, a multi-performance optimization design for FTS systems with fully decoupled motion was achieved. The open-loop test of prototype validates the estimated strokes with low coupling and high natural frequencies. In closed-loop testing, the results demonstrate a minimal tracking error of <span><math><mrow><mo>±</mo><mn>0</mn><mo>.</mo><mn>1</mn><mtext>%</mtext></mrow></math></span> for the Lissajous trajectory, showcasing its precision in tracking desired trajectories for intricate micro/nano-structure formation.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"95 ","pages":"Pages 262-271"},"PeriodicalIF":3.5,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143922113","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}