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

{"title":"Glass thickness testing using Fizeau interferometer with suppression of environmental factors","authors":"Jurim Jeon ,&nbsp;Yangjin Kim ,&nbsp;Yusuke Ito ,&nbsp;Naohiko Sugita ,&nbsp;Kenichi Hibino","doi":"10.1016/j.precisioneng.2024.12.017","DOIUrl":"10.1016/j.precisioneng.2024.12.017","url":null,"abstract":"<div><div>The phase extraction technique used for thickness profiling of transparent glass plates through wavelength-tuning interferometry is susceptible to nonlinear error in phase shift owing to environmental factors, such as vibration and temperature fluctuations. These phase shift nonlinearities cause fluctuations and constant errors in the calculated phase, thereby distorting the original phase information. To address this issue, this study proposed a novel algorithm design method known as the advanced averaging method. This method incorporates the successive averaging technique and complex analysis using <em>Z</em>-transform to suppress phase shift nonlinearity. Additionally, a (7 + 4)-frame phase analysis algorithm was derived by the newly proposed advanced averaging method. Based on numerical analysis, the novel advanced averaging (7 + 4)-frame algorithm outperforms other algorithms in suppressing errors resulting from phase shift nonlinearity. Finally, in a validation experiment, the thickness homogeneity of a precision glass plate was profiled using this newly developed algorithm in conjunction with a large-aperture wavelength-tuning Fizeau interferometer. The repeatability error of the measurement accuracy was 4.563 nm, which is significantly lower than that of other conventional algorithms.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 99-109"},"PeriodicalIF":3.5,"publicationDate":"2025-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287497","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":"Surrogate model-based tool trajectory modification for ultra-precision tool servo diamond turning","authors":"Hao Wu ,&nbsp;YiXuan Meng ,&nbsp;ZhiYang Zhao ,&nbsp;ZhiWei Zhu ,&nbsp;MingJun Ren ,&nbsp;XinQuan Zhang ,&nbsp;LiMin Zhu","doi":"10.1016/j.precisioneng.2024.12.016","DOIUrl":"10.1016/j.precisioneng.2024.12.016","url":null,"abstract":"<div><div>Tool servo diamond turning is extensively used for machining complex-shaped freeform surfaces due to its deterministic material removal capabilities. However, the inherent bandwidth limitations of the current slow slide servo technique lead to significant tracking errors, posing critical challenges to achieving high-efficiency and high-precision fabrication of these intricate surfaces. To address these challenges, this work proposes a novel data-driven surrogate model for tool trajectory modification that predicts servo axis tracking errors and adjusts the reference tool path prior to cutting operations, thereby enabling effective feedforward compensation. A two-dimensional convolutional neural network (2D-CNN) surrogate model is employed to capture the dynamic properties of tracking errors inherent in servo axes, with particular emphasis on the servo axis along the depth-of-cut direction. The predicted tracking errors serve as feedforward compensation terms for the initial reference trajectory, generating the modified diamond tool trajectory. Experimental validation on a commercial three-axis ultra-precision machine tool demonstrates the effectiveness and practical applicability of this trajectory modification method. Comparative results indicate that, with the assistance of the proposed modification method, the peak-to-valley (PV) error for segments of the tracked tool trajectory decreases from 1.29 μm to 0.59 μm, and the root-mean-square (RMS) error decreases from 373 nm to 138 nm; the PV error for the cross-sectional profiles of machined freeform surfaces decreases from 1.25 μm to 0.65 μm, and the RMS error decreases from 196 nm to 117 nm.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 46-57"},"PeriodicalIF":3.5,"publicationDate":"2024-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143286917","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":"Single-point synthesis of compliant mechanisms","authors":"O. Sorgonà ,&nbsp;O. Giannini ,&nbsp;M. Verotti","doi":"10.1016/j.precisioneng.2024.12.012","DOIUrl":"10.1016/j.precisioneng.2024.12.012","url":null,"abstract":"<div><div>In the last decades, several methods have been developed for the synthesis of compliant mechanisms. Generally, the proposed approaches work at the mechanism level, leading to the definition of a compliant structure starting from specific design requirements and constraints. In this paper, a novel <em>point compliance synthesis</em> method for planar systems is presented. The method relies on a different perspective, namely, at the output port level. It starts from the requirements on an already defined compliant structure, modeled as a two-port system, and leads to the design of the suspended body, that serves both as input and output port. The kinetostatics of the elastic suspension is described by resorting to the ellipse of elasticity theory, under the assumptions of linear deflections and linear elastic material. Then, the point compliance synthesis, based on spectral analysis, targets the field of displacements of the suspended body to define the points meeting the design requirements. The synthesis problem is formulated as a non-dimensional algebraic system that always admits real solutions. In particular, the obtained closed-form expressions hold in the general case, for every compliant mechanism. The method is applied to two case studies, at the element and at the mechanism levels, and finite element simulations are performed to test the theoretical results.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 58-69"},"PeriodicalIF":3.5,"publicationDate":"2024-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287495","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":"Enhancing image processing in single-camera two-wavelength imaging pyrometry for advanced in-situ melt pool measurement in laser powder bed fusion","authors":"Md Jahangir Alam,&nbsp;Haolin Zhang,&nbsp;Xiayun Zhao","doi":"10.1016/j.precisioneng.2024.12.013","DOIUrl":"10.1016/j.precisioneng.2024.12.013","url":null,"abstract":"<div><div>For in-situ measurement of the melt pool (MP) temperature profile in the laser powder bed fusion (LBPF) additive manufacturing (AM) process, a new technology is the single-camera two-wavelength imaging pyrometry (STWIP). Accurate temporally and spatially resolved MP temperature field measurement using this STWIP method requires a precise profiling of pixel-wise two-wavelength intensity ratio, which is highly dependent on optical alignment, and camera's spectral sensitivity, among other factors. Thus, it is essential to develop an accurate, robust, and fast transformation method for reliable and effective mapping of two-wavelength images acquired from the STWIP system. In this work we propose a Blob analysis-based MP guided Image Transformation (BMPIT) method as opposed to the typical feature detector descriptor-based image transformation approach like KAZE. The BMPIT's performance is assessed and compared with the KAZE in terms of efficiency, execution time, accuracy, and robustness. An experiment using a standard calibrated tungsten filament strip lamp is done to validate the effectiveness of BMPIT. Compared to the KAZE, the BMPIT successfully transformed 100 % of the MP images with higher accuracy and faster speed. It is also shown that the BMPIT is a robust technique for image transformation, unaffected by the image size, MP position, and surrounding noise. Moreover, experimental ground truth data collected using Type C thermocouples implanted into an Inconel-718 build plate are used to further validate the LPBF MP temperature estimation accuracy of BMPIT-aided STWIP. Unlike KAZE, temperature estimated by BMPIT agrees well (error &lt;5 %) with both the lamp and thermocouple experiments. BMPIT is an appealing alternative for online measurement due to its reduced execution time, it takes only one fifth of the time that KAZE takes to transform two-wavelength images. In addition, the BMPIT can be used to calculate MP width, which is validated by comparing with ex-situ characterization. It enables a high level of agreement (with an error less than 1.89 %) between MP images of two wavelengths. Overall, the BMPIT greatly improves STWIP image processing, allowing for measuring MP temperature and morphology more rapidly, accurately, and precisely. The developed BMPIT approach can be employed as part of a STWIP-feedback LPBF process control system to improve the quality of additively manufactured metal products.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 1-17"},"PeriodicalIF":3.5,"publicationDate":"2024-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143286916","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 wear mechanism of high-entropy alloy coated tools and grain evolution in micro-cutting of TC4 titanium alloy","authors":"Ping Zhang ,&nbsp;Shunxiang Wang ,&nbsp;Junbao Zhang ,&nbsp;Tengfei Zhang ,&nbsp;Guohong Li","doi":"10.1016/j.precisioneng.2024.12.010","DOIUrl":"10.1016/j.precisioneng.2024.12.010","url":null,"abstract":"<div><div>This study investigates the wear mechanisms and grain refinement patterns of CoCrFeNiAlX series high-entropy alloy-coated tools during the micro-cutting of TC4 titanium alloy. Three coatings were selected: CoCrFeNiAl (Al1), CoCrFeNiAl0.6 (Al0.6), and CoCrFeNi (Al0). Using DEFORM-3D for three-dimensional cutting simulations, the effects of coating type and thickness on tool wear and grain refinement in the cutting deformation zone were analyzed. Results show that at a coating thickness of 10 μm, all types of coated tools exhibited minimal wear depth. Al0.6 coating was significantly affected by thickness, with wear depth increasing by up to 10 %. Dual-layer coatings performed better in reducing wear and maintained good wear resistance even at higher thicknesses, whereas single-layer coatings showed a marked increase in wear depth and rate with increased thickness. As coating thickness increased, the number of dynamic recrystallization (DRX) grains at location P2 decreased for single-layer coated tools. Dual-layer coated tools showed stable DRX numbers, fluctuating between 400 and 600 at P2. Compared to single-layer coatings, dual-layer coatings exhibited higher DRX grain counts across all cutting deformation zones, especially in the third deformation zone, demonstrating superior mechanical properties and recrystallization effects. Dual-layer coated tools also displayed good stability with minimal grain size variation, with Al1 as the inner layer contributing to more stable grain sizes. The Al0.6+Al1 coating experienced significant grain size growth in the third deformation zone due to stress concentration.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 253-264"},"PeriodicalIF":3.5,"publicationDate":"2024-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176764","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 of focus variation microscopy immunity to vibrations","authors":"Aalim M. Mustafa,&nbsp;Hussam Muhamedsalih,&nbsp;Dawei Tang,&nbsp;Prashant Kumar,&nbsp;Liam Blunt,&nbsp;Jane Jiang","doi":"10.1016/j.precisioneng.2024.12.014","DOIUrl":"10.1016/j.precisioneng.2024.12.014","url":null,"abstract":"<div><div>Optical metrology plays a vital role in a wide range of research fields and for inspection in manufacturing industries. At present, the market offers a variety of optical metrology instruments, such as interferometers, confocal microscopes, and focus variation (FV) instruments. Although interferometers have the highest precision among optical metrology instruments, they are very sensitive to vibrations/environmental disturbances. On the other hand, focus variation technology is widely recognised for its robustness to vibrations (compared to interferometers), but so far, there is no study in place investigating the vibration frequency and amplitude limits within which focus variation instruments operate optimally in the presence of vibrations. To our knowledge, this article is the first study that aims to estimate quantitatively the immunity of focus variation instruments to vibration. This paper presents theoretical simulations to investigate how vibrations affect the FV principle of evaluating the best-focused images to calculate surface topography. The simulations were verified with practical results from an experimental FV setup built in the lab, and the two results match very well. Afterwards, vibration experiments were performed using the state-of-the-art focus variation instrument, Alicona InfiniteFocus G5, to measure the surface roughness of the Microusurf 334 comparator from Rubert &amp; Co. LTD under vibrations induced by the P-840.2 piezoelectric actuator from Physik Instrumente (PI). The experiments were performed at different frequencies by incrementally changing the vibration amplitudes, pre-planned as a function of the depth of field (DoF) of each magnification lens (10x to 100x). It is observed that the FV system generates 100 % “bad-data” when the vibration amplitude exceeds three times the DoF of the used objective lens at low frequencies (i.e. as early as 5 Hz).</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 87-98"},"PeriodicalIF":3.5,"publicationDate":"2024-12-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287496","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":"Primary calibration method for laser Doppler vibrometers using electro-optical modulator","authors":"H. Nozato,&nbsp;W. Kokuyama,&nbsp;T. Shimoda,&nbsp;H. Inaba","doi":"10.1016/j.precisioneng.2024.12.015","DOIUrl":"10.1016/j.precisioneng.2024.12.015","url":null,"abstract":"<div><div>In this study, we propose a primary calibration method for laser Doppler vibrometers using an independent reference heterodyne laser interferometer and electro-optical modulator up to 1 MHz, and demonstrate its performance under the measurement uncertainties of velocity sensitivity and phase shift at different frequencies. To validate the proposed method, we compared its results with the comparison calibration results of a back-to-back accelerometer. Consequently, we confirmed the reliability of the proposed primary calibration method within the expanded uncertainty range.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 204-215"},"PeriodicalIF":3.5,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287499","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 and analysis of biomimetic micro-groove aerostatic bearing inspired by Populus euphratica veins for enhanced load capacity and stiffness","authors":"Kai Feng,&nbsp;Guoqing Wang,&nbsp;Chenhui An,&nbsp;Rui Chen,&nbsp;Wenjun Li,&nbsp;Shuai Huang,&nbsp;Jiqiang Jiang","doi":"10.1016/j.precisioneng.2024.12.011","DOIUrl":"10.1016/j.precisioneng.2024.12.011","url":null,"abstract":"<div><div>Pocketed orifice-restrictor aerostatic bearings (PORABs) are widely used in ultra-precision machining, metrology, and semiconductor manufacturing. However, the pocket limits further improvement in load capacity and stiffness. The complex vortices within the pocket can induce micro-vibration of aerostatic bearings, which is harmful to the positioning accuracy of state-of-the-art equipment. This contradicts the requirements of state-of-the-art equipment for greater load capacity, stiffness, and stability. A novel biomimetic micro-groove aerostatic bearings (MGABs) inspired by Populus euphratica veins is proposed. The design of the micro-groove provides a transmission channel for the high-pressure air near the orifice. Numerical results, while maintaining the same dead volume, indicate that the high-pressure area of the MGABs covers most of the bearing surface compared to the PORABs. Among the MGABs, the dentate fan-shaped bearing (DFS-B) has a more uniform and larger high-pressure area. Theoretical results indicate that the maximum load capacity of DFS-B increased by 139.82 % and maximum stiffness increased by 484.62 % compared to the PORABs while maintaining a relatively lower maximum mass flow rate. Additionally, the flow field characteristics results show that vortices are difficult to form in the DFS-B. The PORABs and MGABs are manufactured using ultra-precision machining and laser technology. Static and dynamic test-beds are constructed to test the bearings. The experimental results validated the effectiveness of the solution model and demonstrated that the MGABs are superior to PORABs in load capacity, stiffness, and stability.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 18-36"},"PeriodicalIF":3.5,"publicationDate":"2024-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143286919","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 generation of contour parallel toolpaths for 2.5D closed cavity based on accurate discrete medial axis transform","authors":"Peng Shi,&nbsp;Xiaomeng Tong,&nbsp;Hongquan Qu,&nbsp;Maolin Cai","doi":"10.1016/j.precisioneng.2024.11.014","DOIUrl":"10.1016/j.precisioneng.2024.11.014","url":null,"abstract":"<div><div>Contour parallel toolpaths are the most common machining strategies for 2.5D features. To enhance the machining efficiency, different cutting paths for various tool combinations should be considered. However, existing algorithms have paid limited attention to multi-tool cutting, which is nevertheless an industrial practice in roughening and finishing. This paper proposes a rapid generation method for contour parallel toolpaths based on an accurate two-dimensional discrete medial-axis transform (MAT) for complex closed cavities. The accurate discrete MAT was refined using the Delaunay triangulation (DT) method. According to the definition of MAT, the calculated discrete medial axis (MA) points are adjusted to obtain accurate MA points by iterative method. The accurate discrete MAT obtained served as the basis for the toolpath generation. Contour parallel toolpaths can be rapidly generated by applying the discrete MAT and the proposed toolpath generation method. The resulting toolpaths have been validated to closely match the cutting path obtained through commercial software calculations, which require much higher computational efforts. The proposed method introduces a novel accurate discrete medial axis calculation method and enables the rapid computation of multi-tool combination cutting paths., which is more suitable in toolpath generation, cutting time prediction and toolset optimization in practice.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"92 ","pages":"Pages 231-252"},"PeriodicalIF":3.5,"publicationDate":"2024-12-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143176766","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":"Enhancing pointing accuracy in Risley prisms through error calibration and stochastic parallel gradient descent inverse solution method","authors":"Liangzhu Yuan ,&nbsp;Jinying Li ,&nbsp;Yue Fan ,&nbsp;Jianliang Shi ,&nbsp;Yongmei Huang","doi":"10.1016/j.precisioneng.2024.12.008","DOIUrl":"10.1016/j.precisioneng.2024.12.008","url":null,"abstract":"<div><div>High-precision pointing is crucial in evaluating the effectiveness of beam control technology. However, devices utilizing compact rotational Risley prisms (RRP) face a challenge in balancing field-of-view (FOV) and pointing accuracy. This study aims to develop a beam pointing model for RRP and enhance pointing accuracy through error calibration using the system identification method. Moreover, the current two-step inverse solution method is inadequate when the beam deflection model includes the prism's tilt error. To overcome this limitation, this study proposes a stochastic parallel gradient descent (SPGD) inverse solution method to further improve the system's pointing accuracy. A RRP system with a FOV of <span><math><mrow><mo>±</mo><msup><mn>15</mn><mo>∘</mo></msup></mrow></math></span> was constructed for experimentation. The results indicate the pointing accuracy is 2.8 arcsec, the angular dynamic range is 46 dB, and the root-mean-square errors (RMSE) in the x- and y-directions are 1.2 arcsec and 0.9 arcsec, respectively. This device exhibits the highest angular dynamic range among existing RRP devices.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 37-45"},"PeriodicalIF":3.5,"publicationDate":"2024-12-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143286918","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}