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

{"title":"Effects of the V-groove property for machining miniature balls using a plate with discontinuous sectors of fixed abrasives","authors":"Xun Lv","doi":"10.1016/j.precisioneng.2025.06.001","DOIUrl":"10.1016/j.precisioneng.2025.06.001","url":null,"abstract":"<div><div>To achieve efficient, high-accuracy machining of miniature balls, this study proposes a novel lapping method using a plate with discontinuous sectors of fixed abrasives (PDSFA). By varying friction coefficients across different plate sectors, the method promotes the formation of uniform, full-coverage lapping trajectories on the ball surface, enhancing machining accuracy and efficiency. A kinematic model is developed to analyze the properties of the eccentric V-groove and its effect on the distribution of the machining trajectory. Simulation and experimental results confirm that optimizing groove eccentricity significantly improves trajectory uniformity and coverage. An experimental platform was constructed to evaluate the performance of the PDSFA approach using GGr15 bearing steel miniature balls. At an optimal groove eccentricity degree of 0.3, after 6 h of lapping, the balls achieved an average roundness (<em>RON</em>_<em>t</em>) of 0.118 μm and surface roughness (<em>R</em>_<em>a</em>) of 17.5 nm. A subsequent 3-h polishing process further reduced <em>RON</em>_<em>t</em> to 0.082 μm (±0.02 μm) and <em>R</em>_<em>a</em> to 9 nm (±0.8 nm), demonstrating the method's effectiveness and precision.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 147-159"},"PeriodicalIF":3.5,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279867","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 high resolution, fast response speed, and long-stroke hybrid flexible focusing mechanism of advanced optical imaging system driven by an ultrasonic motor","authors":"Dengxian Zhou,&nbsp;Zhiyuan Yao,&nbsp;Jianing Xu,&nbsp;Xiaoniu Li","doi":"10.1016/j.precisioneng.2025.06.002","DOIUrl":"10.1016/j.precisioneng.2025.06.002","url":null,"abstract":"<div><div>Focusing mechanisms are critical components of optical systems, such as airborne remote sensing, deep space exploration, and biomedical engineering. Traditional focusing mechanisms driven by electromagnetic motors or piezoelectric stack actuators struggle to achieve high resolution, fast response speed, and long stroke simultaneously, falling short of meeting the requirements for high-resolution and high-speed imaging mainly because electromagnetic motors have poor precision and piezoelectric stack actuators have limited stroke. To address these challenges, this study proposes a novel flexible focusing mechanism driven by an ultrasonic motor, integrating a double-bending mode ultrasonic motor with a long-stroke flexible mechanism. First, a compact double-bending mode ultrasonic motor is designed and optimized to accommodate limited vertical space. The design prioritizes a reduced height while maintaining stable performance. Second, based on the pseudo-rigid-body model, the parametric and structural design of the flexible mechanism is completed using a hybrid configuration that incorporates a parallelogram flexible mechanism. Third, the dynamic model of the moving platform is established. Through simulation, it is observed that driving the flexible mechanism improves stability by 83.34 % compared to a rigid body. This helps to improve the accuracy of the focusing mechanism. A prototype of the focusing mechanism is fabricated and tested. The experimental results show that the focusing mechanism's response time, resolution, and stroke are 40 ms, 90 nm, and ±5 mm. The proposed focusing mechanism demonstrates the capability of nanometer-scale focusing with nanometer precision in a millimeter stroke.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 65-79"},"PeriodicalIF":3.5,"publicationDate":"2025-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144253412","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 robot-assisted calibration procedure for Optical Coordinate Measuring Systems","authors":"Connor Gill ,&nbsp;Adam Haynes ,&nbsp;Laura Justham ,&nbsp;James Dobrzanski ,&nbsp;Richard Buswell ,&nbsp;Niels Lohse ,&nbsp;Peter Kinnell","doi":"10.1016/j.precisioneng.2025.05.016","DOIUrl":"10.1016/j.precisioneng.2025.05.016","url":null,"abstract":"<div><div>Metrology systems in general require calibration and verification procedures to provide their user with confidence in measured results. Large Volume Metrology (LVM) applications pose a unique challenge in this regard due to their large scale and ever-increasing accuracy requirements. Current methods for calibration in LVM generally require either a cumbersome artefact, costly instrumentation, or a time-consuming procedure which limits their applicability. Presented in this article is a calibration procedure for Optical Coordinate Measuring Systems (OCMSs) for use within LVM applications. The proposed approach enables the assessment of point-to-point accuracy of a system by triangulation of a single, low-cost ball bar artefact, removing the need for a high-accuracy reference measurement system. A robotic system is used to manipulate the artefact to positions throughout the measurement volume, and by connecting virtual points in 3D space with an artefact of known length, a mesh with fully defined edge lengths is formed. Relating the measured positions of each point in this mesh with the nominal positions, the point-to-point errors of the measurement system are calculated. The capability of this approach is demonstrated with a numerical simulation, where it is shown to be capable of calibrating an arbitrarily large volume, with residual errors converging to the random noise of the system. Finally, an implementation is shown using a real-world commercial Optical Motion Capture system, where, by applying a correction according to the identified point-to-point errors, the mean error of a 1.2x1.0x1.5 m measurement volume was reduced from 0.601 mm to 0.379 mm. A thorough search of the relevant literature indicates that this is the first attempt to use a single ball bar artefact and robotic system for the systematic point-to-point calibration of a measurement system.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 55-64"},"PeriodicalIF":3.5,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144253411","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 new inchworm piezoelectric rotary motor with optimized vibration and frictional slipping effects","authors":"Yingjie Jia ,&nbsp;Yuzhang Wei ,&nbsp;Hui Tang ,&nbsp;Xin Chen ,&nbsp;Zhi-xin Yang ,&nbsp;Yanling Tian","doi":"10.1016/j.precisioneng.2025.05.018","DOIUrl":"10.1016/j.precisioneng.2025.05.018","url":null,"abstract":"<div><div>Inchworm rotary motion with high-precision and large-stroke properties is increasingly required in micro/nano alignment applications. However, the precision of current piezoelectric inchworm motors is severely deteriorated by poor step consistency under different frequencies because of undesired contact vibration and frictional slipping. In this article, an inchworm piezoelectric rotary motor with high step consistency is developed. A new compliant soft contact and rotary mechanism (CSCRM) is designed and optimized to achieve soft and stable contact, and then rotate the output platform in sequence, passively suppressing vibration with two-level compliant contact stiffness. Importantly, to analyze the triggering condition of frictional slipping, a contact-friction model is presented to build the relationship between the driving signals (including acceleration) and the friction. Then, the boundary conditions of frictional slipping are deduced from the contact-friction model and used to optimize driving signals in value, sequence and shape. FEA simulation verifies the optimized results of mechanical parameters. In addition, a prototype is fabricated and tested with comparative experiments. The experimental results uniformly confirm that the developed piezoelectric rotary motor can achieve microradian resolution with 3.3 <span><math><mi>μ</mi></math></span>rad, speed of 42.81 mrad/s, and load-bearing capacity of 2 kg in a highly linear and stable manner. More importantly, the contact vibration and frictional slipping are nearly eliminated, leading to almost no rollback and highest step consistency among current literature, i.e., 93% within 100 Hz. It is also worth noting that the designed motor can continuously work across different frequencies without readjusting the initial gap.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 123-133"},"PeriodicalIF":3.5,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144270028","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":"Optimization design and experimental study of the flow field for precision ECM of blisks","authors":"Shen Moqi,&nbsp;Hui Libing,&nbsp;Zhang Zhichun,&nbsp;Liu Jia,&nbsp;Zhu Di","doi":"10.1016/j.precisioneng.2025.05.022","DOIUrl":"10.1016/j.precisioneng.2025.05.022","url":null,"abstract":"<div><div>In the electrochemical machining (ECM) of the blisk, each blade must meet the machining requirements due to the blisk being an integral component. Therefore, maintaining the stability of the machining process is of great significance. However, in the current stage of the precision ECM process of blisks, it has been observed that blades may experience current fluctuation and occasional burn marks on the blade surface. In order to explore the causes of this phenomenon and solve the problem, this paper establishes a fluid-structure interaction mathematical model suitable for high-speed flow and geometric deformation during electrolytic precision machining. Meanwhile, a newly designed flow field and corresponding integrated fixture is proposed. Simulation results indicate that the new flow field successfully reduced the flow velocity difference between the concave and convex sides of the blade by 71 %, the equivalent stress on the blade decreased by 60 %, and blade deformation was reduced by 70 %. Meanwhile, corresponding experimental studies have been carried out. The experiment results show that the blade deformation decreased by 68 % with the new flow field form. 3D microscopic inspection and line roughness testing of the blade surface quality demonstrated that new flow field eliminated the current fluctuation and occasional burn marks phenomenon, and greatly enhanced the stability of the electrochemical fine machining process and the surface quality of the blades.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 94-111"},"PeriodicalIF":3.5,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261421","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":"Design, modeling and control of a 3 degree-of-freedom positioning system for high-precision 3D inline-metrology","authors":"Daniel Pechgraber ,&nbsp;Ernst Csencsics ,&nbsp;Georg Schitter","doi":"10.1016/j.precisioneng.2025.05.015","DOIUrl":"10.1016/j.precisioneng.2025.05.015","url":null,"abstract":"<div><div>This paper presents the mechatronic design and control of a 3 degree-of-freedom (3-DoF) precision positioning system for high-precise optical 3D inline-metrology based on a dual-stage approach. It overcomes limitations of common optical 3D measurement systems due to motion blur by precisely positioning measurement systems on a metrology platform with respect to a (moving) measurement sample and additionally extends their measurement range. A comprehensive mathematical model of the system is derived and simplified to linear models suitable for classical linear control design methods. Using a modal analysis approach for system decoupling, a decentralized control scheme with individual Single-Input Single-Output controllers is developed for precisely controlling the metrology platform position in 3 DoFs. Experimental measurements on the prototype system demonstrate a maximum measurement error resulting from the positioning system of down to <span><math><mrow><mn>7</mn><mo>.</mo><mn>5</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span> to <span><math><mrow><mn>12</mn><mo>.</mo><mn>3</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span> (rms) during platform motion of up to 100 mm/s over a large inspection area (0.7 m × 0.5 m), as well as 147 nm (rms) error during static positioning.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 160-169"},"PeriodicalIF":3.5,"publicationDate":"2025-06-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144291309","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":"Error analysis and correction of snapshot phase-shift lateral shear interferometer based on dual quality map guided ellipse fitting","authors":"Siqi Wang ,&nbsp;Hang Yuan ,&nbsp;Ailing Tian ,&nbsp;Bingcai Liu ,&nbsp;Hongjun Wang ,&nbsp;Xueliang Zhu ,&nbsp;Jiaming Su ,&nbsp;Bei Zhou ,&nbsp;Jinyao Hou ,&nbsp;Bo Liu","doi":"10.1016/j.precisioneng.2025.05.025","DOIUrl":"10.1016/j.precisioneng.2025.05.025","url":null,"abstract":"<div><div>To enable adjustable sensitivity in lateral shearing interferometry, a tunable snapshot phase-shifting lateral shearing interferometry system based on a liquid crystal polarization grating (SPS-LCPG-LSI) was developed. However, in high-precision surface measurements, system phase-shift errors introduced by the LCPG and the pixelated phase mask (PPM) can significantly affect measurement accuracy. To ensure precision, the sources of various system phase-shift errors in the SPS-LCPG-LSI system were analyzed. A Dual-Quality map-guided (Dual-QMG) ellipse fitting algorithm was developed to correct phase-shift errors under varying error magnitudes and intensity distributions. Simulations and experimental results validated the accuracy and feasibility of the Dual-QMG correction algorithm.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 44-54"},"PeriodicalIF":3.5,"publicationDate":"2025-05-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144204773","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":"Nano surface generation by single point diamond turning for low-pressure diffusion bonding of copper","authors":"Dipin Kumar R ,&nbsp;S. Aravindan ,&nbsp;Kundan Kumar Prasad ,&nbsp;Gufran S. Khan","doi":"10.1016/j.precisioneng.2025.05.027","DOIUrl":"10.1016/j.precisioneng.2025.05.027","url":null,"abstract":"<div><div>This study has demonstrated a combination of single-point diamond turning (SPDT) and solid-state diffusion bonding (SSDB) to achieve low-pressure joining of Cu plates. SPDT on the faying surfaces has resulted in nano-level surface roughness of Sa 1.56 nm and Ra 1.32 nm. Diffusion bonding experiments were performed by varying bonding temperatures from 600 °C to 800 °C and at a low bonding pressure of 4 MPa. It was interesting to note that a low-temperature bonding at 600 °C has resulted in a bonding ratio of 92.2 %, and it significantly enhanced to 98.4 % at 800 °C. Complete grain boundary migration was observed along the joint interface for the sample bonded at 800 °C. The shear load for joint failure increased from 13.06 kN to 18.36 kN with an increase in bonding temperature, which was correlated with the microstructural observation. The fractography study indicated a ductile mode of failure. Low-pressure diffusion bonding of the Cu plate with integrated channels was successfully demonstrated without deforming the channels. Precision alignment of the arrayed channels for conformal cooling applications could be achieved using a combination of SPDT and SSDB, which would be challenging with other joining techniques.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 19-30"},"PeriodicalIF":3.5,"publicationDate":"2025-05-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144196451","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":"Error modeling, parameter identification and non-parametric calibration of a 3PUS/S spherical parallel manipulator","authors":"Ehsan Savaee,&nbsp;Ali Rahmani Hanzaki","doi":"10.1016/j.precisioneng.2025.05.023","DOIUrl":"10.1016/j.precisioneng.2025.05.023","url":null,"abstract":"<div><div>In comparison to serial manipulators, parallel robots have many applications in industries due to their unique characteristics such as larger stiffness-to-mass and payload-to-weight ratios. Since, the accuracy and error reduction of the manipulators are very prominent, various methods have been proposed to calibrate parallel robots with different structures so far. This article presents the kinematic parameters estimation and non-parametric calibration of a 3PUS/S spherical parallel manipulator. In this regard, the kinematic equations of the manipulator are derived to identify the error sources, then an error model is developed to correlate the errors of the robot's outputs to the inaccuracies of the manipulator's structural parameters and joint variables. In addition, a prototype of the manipulator is designed and made to collect suitable data sets for calibration, then many experiments in the robot's workspace are performed, and the input and output values are recorded by encoder and AHRS sensors with high accuracy. Next, the estimation of geometric parameters is fulfilled by an optimization method, then the artificial neural network is employed for non-parametric calibration. The results show that the geometric calibration based on parameter estimation and non-parametric calibration could improve the robot accuracy about 73 % and 96 %, respectively.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 31-43"},"PeriodicalIF":3.5,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144204772","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":"Synchronous-spark series-multi-channel electrical discharge machining","authors":"Samuel Mander,&nbsp;Philip Koshy","doi":"10.1016/j.precisioneng.2025.05.014","DOIUrl":"10.1016/j.precisioneng.2025.05.014","url":null,"abstract":"<div><div>Generating multiple discrete discharges per voltage pulse application is an intriguing approach to enhancing the low material removal rate (MRR) inherent to electrical discharge machining (EDM). To this end, this paper presents a novel, scalable series-EDM system that generates synchronous unipolar discharges across multiple channels per voltage pulse, which enables the concurrent machining of several workpieces. When tested on a twin tool-work pair, this system increased MRR by 1.75 times and doubled the power efficiency, relative to a conventional single-channel system. This highlights its significant potential in addressing the low MRR and the energy-intensive nature of EDM.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"96 ","pages":"Pages 1-5"},"PeriodicalIF":3.5,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144184466","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}