Manufacturing Letters最新文献_第10页

Effects of processing parameters on joining strength of 316L-Cu interface in multi-materials laser powder bed fusion 工艺参数对多材料激光粉末床熔合316L-Cu界面连接强度的影响

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.092

Jiaqi Yang, Dehao Liu

This study examines the impact of processing parameters on the joining strength and interfacial characteristics of 316L stainless steel-copper (Cu) interfaces fabricated using laser powder bed fusion. The integration of 316L and copper is critical for engineering applications that require a combination of mechanical strength, thermal conductivity, and corrosion resistance. Systematic experiments are conducted to evaluate the effects of varying laser power and scanning speed on interfacial properties. The 316L-Cu interfaces are characterized using optical microscopy, energy-dispersive X-ray spectroscopy (EDS), and microhardness testing to assess morphological and elemental features. A lap shear test was conducted to evaluate the mechanical strength of the joint, revealing an ultimate shear strength of 42.95 MPa for the sample with the optimal printing parameters in this work. The results indicate that increased volumetric energy density enhances interfacial bonding by promoting elemental diffusion and reducing porosity. However, challenges such as residual stresses and thermal expansion mismatch still affect interface quality. This research provides insights into the optimization of laser powder bed fusion parameters to improve the mechanical performance and reliability of multi-material components, advancing their applicability in diverse industrial sectors.

研究了工艺参数对激光粉末床熔接316L不锈钢-铜（Cu）界面连接强度和界面特性的影响。316L和铜的集成对于需要结合机械强度、导热性和耐腐蚀性的工程应用至关重要。通过系统实验研究了不同激光功率和扫描速度对界面性能的影响。利用光学显微镜、能谱x射线能谱（EDS）和显微硬度测试对316L-Cu界面进行了表征，以评估其形态和元素特征。通过搭接剪切试验对接头的力学强度进行了评价，得到了最佳打印参数下试样的极限抗剪强度为42.95 MPa。结果表明，增大的体积能量密度通过促进元素扩散和降低孔隙率来增强界面结合。然而，残余应力和热膨胀失配等问题仍然影响着界面质量。本研究为优化激光粉末床熔合参数，提高多材料部件的力学性能和可靠性，提高其在不同工业领域的适用性提供了见解。

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引用次数: 0

Prediction of residual stresses induced in turning – Influence of cutting tool geometry 车削过程中残余应力的预测。刀具几何形状的影响

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.075

Joel Rech , Sangil Han , Alexis Cavard , Marc Raffestin , Frédéric Valiorgue

It has long been recognised that machining processes induce residual stresses in machined surfaces. This article focuses on the longitudinal turning process of the martensitic stainless steel 15-5PH. The aim is to investigate the influence of tool geometry, specifically rake angle and edge sharpness, on surface residual stresses. Three turning tools were studied both experimentally and through numerical simulations using the MISULAB software. The results show that the geometry of the cutting tool does not significantly affect the residual stress state in the outer layer. On the contrary, edge radius and rake angle determine the thickness of the affected layer as well as the intensity of the compression peak below the outer layer. Cutting tools with a large edge radius and a small rake angle result in a thick affected depth, characterised by a deep compression peak below the outer layer. The trends observed experimentally are well predicted by the numerical simulations, providing new insights for the design of new cutting tools dedicated to the optimisation of the residual stress state.

人们早就认识到，加工过程会在加工表面产生残余应力。本文主要研究了马氏体不锈钢15-5PH的纵向车削工艺。目的是研究刀具几何形状，特别是前角和边缘锐度对表面残余应力的影响。利用MISULAB软件对三种车削刀具进行了实验研究和数值模拟。结果表明，刀具几何形状对外层残余应力状态影响不显著。相反，边缘半径和前倾角决定了受影响层的厚度以及外层以下压缩峰的强度。具有大边缘半径和小前角的切削工具会导致较厚的受影响深度，其特征是外层以下的深压缩峰值。数值模拟很好地预测了实验观察到的趋势，为优化残余应力状态的新型切削刀具的设计提供了新的见解。

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引用次数: 0

ArcSaw – A new tool for rapid machining of sculpted surfaces in aramid honeycomb ArcSaw -一种快速加工芳纶蜂窝表面的新工具

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.072

Andrew L. Schmidt, David D. Gill, Rowan O. Dickerson

A novel cutting tool, called the ArcSaw, is proposed, developed, and tested to address the high cost and long cutting times for aramid honeycomb sculpted surfaces. The tool utilizes a circular or elliptical band of cutting teeth to quickly remove large quantities of aramid honeycomb in a roughing process. The band, simulating a very-large radius ball end mill, can remove large quantities of honeycomb in a very short timeframe. However, instead of shredding all of that aramid into dust, as is done with current roughing cutters, this process removes the material in strips which pose a much-reduced risk to the machine’s moving parts, the operator’s lungs, and general facility cleanliness. In the development of the process, a simple FEA model was developed to help with an understanding of the process, the effect of cutting tooth spacing, and the magnitude of cutting forces. This model was compared with preliminary cutting tests on a traditional bandsaw using high speed videography and a force dynamometer. Once the ArcSaw prototype design was completed, an ArcSaw was mounted in a vertical machining center and used in a cutting test. Despite some challenges with out-of-round blades, the results of the cutting test were shown to have reasonable agreement with the FEA analysis. Strengths and opportunities for improvement of the ArcSaw design were catalogued.

一种名为ArcSaw的新型切割工具被提出、开发和测试，以解决芳纶蜂窝雕刻表面的高成本和长切割时间。该工具利用圆形或椭圆形的切削齿带，在粗加工过程中快速去除大量芳纶蜂窝。该带模拟了一个非常大半径的球立铣刀，可以在很短的时间内去除大量的蜂窝。然而，与现有的粗加工切割机将所有芳纶粉碎成灰尘不同，这种方法将材料条状去除，大大降低了对机器运动部件、操作员肺部和一般设施清洁度的风险。在开发过程中，开发了一个简单的有限元模型，以帮助理解过程，切削齿间距的影响，以及切削力的大小。利用高速摄像和力测仪将该模型与传统带锯的初步切割试验进行了比较。一旦ArcSaw原型设计完成，ArcSaw被安装在一个垂直加工中心，并用于切割测试。尽管外圆叶片存在一些挑战，但切割试验结果与有限元分析结果基本一致。对ArcSaw设计的优势和改进机会进行了分类。

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引用次数: 0

Scanning speed-induced surface roughness change and its impact on the corrosion resistance of IN718 fabricated by laser powder bed fusion 扫描速度引起的表面粗糙度变化及其对激光粉末床熔合IN718耐蚀性的影响

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.090

Bo Zhao , Kateland Hutt , Zilong Zhao , Pai Wang , Hitomi Yamaguchi , Shuaihang Pan

This study investigates the influence of scanning speed on surface roughness and its impact on the corrosion resistance of IN718 fabricated using Laser Powder Bed Fusion (LPBF). Three scanning speeds (760 mm/s, 800 mm/s, and 840 mm/s) were applied, and the surface roughness, microhardness, and electrochemical properties were analyzed. The results reveal a significant discrepancy between the optimal scanning speed for achieving superior mechanical properties and that required for maximizing the LPBF-fabricated alloy’s corrosion resistance performance. More specifically, this study highlights the critical role of scanning speed on the corrosion behavior of LPBF IN718, providing practical guidance and insights for achieving the simultaneous enhancement of both mechanical properties and corrosion resistance by printing parameter optimization in LPBF-fabricated materials.

研究了扫描速度对激光粉末床熔敷（LPBF）制备的IN718表面粗糙度的影响及其对耐蚀性的影响。采用760 mm/s、800 mm/s和840 mm/s三种扫描速度，分析了表面粗糙度、显微硬度和电化学性能。结果表明，获得优异力学性能的最佳扫描速度与最大化lpbf制备合金耐腐蚀性能所需的最佳扫描速度之间存在显著差异。更具体地说，本研究强调了扫描速度对LPBF IN718腐蚀行为的关键作用，为通过优化LPBF制造材料的打印参数来实现机械性能和耐腐蚀性的同时增强提供了实践指导和见解。

引用次数: 0

Fabrication of wire-grid polarizer with glass molded nanograting structure 玻璃模压纳米光栅结构线栅偏光片的制备

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.028

Chengjun Jin , Young Kyu Kim , Hyungjum Jang , Xun Lu , Seok-min Kim

Wire grid polarizers (WGPs) are essential in photonic applications such as laser optical systems, imaging systems, and displays due to their high polarization efficiency and durability. Conventional WGPs fabricated on polymer substrates face limitations in optical transmittance, mechanical stability, and thermal durability. This study introduces a cost-effective and scalable method for fabricating WGPs on glass nanograting structures using Vitreous Carbon (VC) molds and oblique angle deposition (OAD) of aluminum. The proposed process addresses the shortcomings of polymer-based WGPs while enabling large-area production. The VC mold was fabricated through a multi-step replication and carbonization process. A silicon master with nanograting features (500 nm pitch, 250 nm height, 50 % duty cycle) was prepared using reactive ion etching and KrF laser photolithography. A polymer template was replicated via UV imprinting, and a furan precursor was replicated from the polymer template through a thermal curing process. A VC mold with a nanograting cavity (400 nm pitch, 140 nm height) was obtained by a carbonization process at 1000 °C in a nitrogen-purged environment. Glass nanogratings were then formed by molding soda-lime glass at 730 °C under 1.84 MPa, with SEM analysis confirming successful nanoscale replication. An aluminum layer was deposited on the glass nanograting using the OAD process, with optimized flux angles (<70°) to minimize sidewall deposition and prevent isolated nanorods. The fabricated WGP exhibited a transverse-magnetic wave transmittance of over 40 % and an extinction ratio of ∼40 at 600 nm, which is similar to the simulation results for the glass WGP model with slight sidewall deposition. Although the pitch of the fabricated WGPs were not suitable for visible light applications, this study demonstrates the feasibility of WGPs with directly molded glass nanograting structures, offering advantages in cost, scalability, and durability. The proposed method is promising for advancing photonic applications.

由于其高偏振效率和耐用性，线栅偏振器（WGPs）在激光光学系统、成像系统和显示等光子应用中至关重要。在聚合物基板上制造的传统WGPs在透光率、机械稳定性和热耐久性方面存在局限性。本研究介绍了一种在玻璃纳米光栅结构上使用玻璃体碳（VC）模具和铝的斜角沉积（OAD）制造WGPs的成本效益高且可扩展的方法。该工艺解决了聚合物基WGPs的缺点，同时实现了大面积生产。通过多步复制和碳化工艺制备了VC模具。采用反应离子刻蚀和KrF激光光刻技术制备了具有纳米光栅特征（500 nm间距，250 nm高度，50% %占空比）的硅母片。采用紫外印迹技术复制聚合物模板，并通过热固化工艺从聚合物模板中复制呋喃前驱体。在氮气净化环境下，在1000 °C下进行炭化工艺，得到了具有纳米光栅腔（间距400 nm，高度140 nm）的VC模具。然后，在730 °C和1.84 MPa的温度下，用钠钙玻璃模压形成纳米玻璃光栅，SEM分析证实了纳米级复制的成功。采用OAD工艺在玻璃纳米光栅上沉积了一层铝层，优化了通量角（<70°），以减少侧壁沉积并防止隔离纳米棒。制备的WGP在600 nm处的横磁透射率超过40 %，消光比为~ 40，这与具有轻微侧壁沉积的玻璃WGP模型的模拟结果相似。虽然制作的WGPs的间距不适合可见光应用，但本研究证明了直接模压玻璃纳米光栅结构的WGPs的可行性，在成本，可扩展性和耐用性方面具有优势。该方法有望推进光子应用。

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引用次数: 0

Influence of flexible spindle characteristics on grinding dynamics in HydroFlex grinding: A numerical simulation with experimental validation 柔性主轴特性对HydroFlex磨削动力学的影响：数值模拟与实验验证

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.060

Patrick Chernjavsky , Yumo Wang , Jack Shanks , Rohit Dey , Shun Yu , Xunzhi Xie , Yang Liu , Yihao Zheng

Advanced manufacturing technologies have enabled the production of computer-optimized components with complex internal geometries, efficient fluid transport and cooling, and weight reduction. Polishing these channels is an essential post-processing step to attain precise geometric tolerance and reduce surface roughness, improving fatigue life and corrosion resistance. Conventional polishing methods for complex geometries struggle to maintain uniform performance in long, and tortuous channels and often use harsh acids which negatively impact the environment. HydroFlex has been shown as an effective internal polishing methods with increased adaptability and performance in highly complex geometries. Key to HydroFlex operation is the generation and maintenance of orbital motion, describing the orbit of the grinding wheel around the internal contour of the channel due to grinding, fluid, and spindle forces acting in the grinding zone. In this study, the spindle force was modeled using minimum potential energy method to determine the spindle position and contact point(s) throughout a complex workpiece. Experimental validation utilized a highspeed camera for shaft position and orbital motion capture, and a force sensing to determine the spindle force during orbit and no-orbit conditions. Results indicated that the model was able to predict the shaft position with visual contact point accuracy. A spindle force threshold of 0.19 N was found to overcome the orbital motion. These results suggest that MPE can be used to predict the spindle position and grinding condition based on threshold force for given spindle and workpiece properties.

先进的制造技术使生产具有复杂内部几何形状、高效流体输送和冷却以及减轻重量的计算机优化组件成为可能。抛光这些通道是必不可少的后处理步骤，以获得精确的几何公差，降低表面粗糙度，提高疲劳寿命和耐腐蚀性。传统的复杂几何形状的抛光方法很难在长而曲折的通道中保持均匀的性能，并且经常使用对环境产生负面影响的强酸。HydroFlex已被证明是一种有效的内部抛光方法，在高度复杂的几何形状中具有更高的适应性和性能。HydroFlex操作的关键是轨道运动的产生和维护，轨道运动描述了由于磨削、流体和磨削区域内的主轴力作用，砂轮围绕通道内部轮廓的轨道。在这项研究中，主轴力采用最小势能法建模，以确定主轴位置和接触点(s)在整个复杂的工件。实验验证利用高速相机捕捉轴的位置和轨道运动，并利用力传感器确定在轨和非在轨条件下的主轴力。结果表明，该模型能够以视觉接触点的精度预测轴的位置。发现主轴力阈值为0.19 N以克服轨道运动。这些结果表明，基于给定主轴和工件性能的阈值力，MPE可以用来预测主轴位置和磨削状态。

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引用次数: 0

Formation of graphitic micro-channels on boron-doped diamond electrodes via femtosecond laser irradiation: A Route for controlled sp2 functionalization 飞秒激光在掺硼金刚石电极上形成石墨微通道：可控sp2功能化途径

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.077

Sagarika Banik , R. Ibdhu , N. Arunachalam , M.S. Ramachandra Rao

Diamond is a promising material for electrodes in the field of electrochemical analysis, biosensing, and energy storage. However, the diamond has to be doped with charge carriers like boron to make it a p-type semiconductor material. Creating highly localized and geometrically confined sp² graphitic columns in boron-doped diamonds can improve the electrocatalytic properties of the electrode. In this work, graphitic columns were created on boron-doped diamond using 100 fs laser pulses at 800 nm wavelength. The laser fluence of 8.85–––44.2 J/cm² and the scanning speed of 0.1–1 mm/s were found to be suitable for graphitization. Microstructural analysis of the samples was done using scanning electron microscopy and Raman spectroscopy techniques. The Raman results showed that a suitable fluence of 22.1 J/cm² and graphitization speed of 0.5 mm/s improves the crystallinity of the graphitic column and suppresses the residual diamond content. A four-probe resistivity measurement was done on the graphitic columns to evaluate the resistivity difference. A minimum resistance of 66.39 Ω/sq was observed at a preferred laser fluence of 22.1 J/cm²; with an increase in laser fluence, an increase in the resistivity was observed.

金刚石是电化学分析、生物传感、储能等领域极具潜力的电极材料。然而，金刚石必须掺杂像硼这样的载流子才能成为p型半导体材料。在掺硼金刚石中建立高度局域化和几何受限的sp2石墨柱可以改善电极的电催化性能。在这项工作中，使用800 nm波长的100 fs激光脉冲在掺硼金刚石上形成石墨柱。在8.85 ~ 44.2 J/cm2的激光辐照强度和0.1 ~ mm/s的扫描速度下，石墨化效果较好。利用扫描电子显微镜和拉曼光谱技术对样品进行微观结构分析。拉曼光谱结果表明，22.1 J/cm2和0.5 mm/s的石墨化速度可以提高石墨柱的结晶度，抑制残余金刚石含量。在石墨柱上进行了四探针电阻率测量，以评估电阻率差异。首选激光通量为22.1 J/cm2时，最小电阻为66.39 Ω/sq；随着激光辐照量的增加，观察到电阻率的增加。

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引用次数: 0

Multi-layer multi-variable value stream mapping: A comprehensive framework across operational, environmental, and social layers with integrated KPIs interrelationships 多层多变量价值流映射：跨操作层、环境层和社会层的综合框架，具有集成的kpi相互关系

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.023

Ayoub Heydarzade , Niloofar Rezaei , Seyed Alireza Vaezi , Jaime A. Camelio

Industry 4.0 technologies have increased the complexity and interconnectivity of manufacturing systems, challenging the conventional scope of Value Stream Mapping (VSM). In response, this paper proposes a Multi-Layer Multi-Variable Value Stream Mapping (MLMV-VSM) framework that integrates operational, environmental, and social layers within a single methodology. The approach captures Key Performance Indicators (KPIs) and their interdependencies, enabling more balanced system optimization. Unlike traditional VSM, MLMV-VSM explicitly incorporates human-centric metrics, such as stress and fatigue, along with operational and environmental factors. An illustrative example demonstrates how operator skill development can influence production speed, energy consumption, and ergonomic outcomes, highlighting cross-layer trade-offs and synergies. The paper also addresses practical challenges, including the measurement of social metrics, the prioritization of competing KPIs, and the need for real-time adaptability. Finally, avenues for future work are identified, emphasizing the integration of Industry 4.0 technologies such as the Internet of Things (IoT) and data analytics to support dynamic decision-making and foster sustainable manufacturing practices.

工业4.0技术增加了制造系统的复杂性和互联性，挑战了价值流映射（VSM）的传统范围。作为回应，本文提出了一个多层多变量价值流映射（MLMV-VSM）框架，该框架将运营层、环境层和社会层集成在一个单一的方法中。该方法捕获关键性能指标（kpi）及其相互依赖性，从而实现更平衡的系统优化。与传统的VSM不同，MLMV-VSM明确地结合了以人为中心的指标，如压力和疲劳，以及操作和环境因素。一个说明性的例子说明了操作员技能的发展如何影响生产速度、能源消耗和人体工程学结果，突出了跨层的权衡和协同作用。本文还讨论了实际的挑战，包括社会指标的度量、竞争kpi的优先级以及对实时适应性的需求。最后，确定了未来工作的途径，强调工业4.0技术（如物联网（IoT）和数据分析）的集成，以支持动态决策和促进可持续制造实践。

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引用次数: 0

Development and initial testing of robotic blacksmithing apparatus 机器人锻造设备的开发和初步测试

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.057

Pedro Doukas, Sha Ouyang, Jinjin Ha, Brad Kinsey

Manufacturing-based robotic platforms with various end effectors to replicate different processes can provide cheaper and space efficient point-of-need capabilities. One such process of interest is robotic blacksmithing that can, e.g., provide a means to post-process composite materials with voids and material imperfections that are fabricated through additive manufacturing. In this paper, a robotic forging end effector is developed and used to cold forge, actually coin, an AA6061-T6 block. Analyses of deformation, both experimental and numerical simulations, allows for the changes to the material, hardness, penetration of the strain hardening, and surface properties to be measured. Penetration data provides insight into the thickness and number of material layers that can be deposited in an additive manufacturing process prior to such a post-processing step to affect the material and layer interface characteristics. Analysis of surface properties reveal the physical changes to the metal that affect its material characteristics.

基于制造的机器人平台具有各种末端执行器来复制不同的过程，可以提供更便宜和更节省空间的需求点功能。其中一个令人感兴趣的过程是机器人锻造，例如，它可以提供一种方法来后处理通过增材制造制造的具有空隙和材料缺陷的复合材料。本文研制了一种机器人锻件末端执行器，并将其应用于AA6061-T6块件的冷锻实锻。变形分析，包括实验和数值模拟，允许对材料、硬度、应变硬化的渗透和表面性能进行测量。穿透数据提供了在后处理步骤影响材料和层界面特性之前，可以在增材制造过程中沉积的材料层的厚度和数量。对金属表面特性的分析揭示了影响其材料特性的物理变化。

引用次数: 0

A novel vibration suppressing method for robotic machining by inertial moment actuator using gyroscopic spindle 一种基于陀螺主轴的惯性力矩作动器机器人加工的新型减振方法

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 Epub Date: 2025-09-02 DOI: 10.1016/j.mfglet.2025.06.017

Jongyoup Shim, Jooho Hwang, Seung Guk Baek, Seung Kook Ro

This study presents a novel gyroscopic spindle actuator designed for vibration suppression in robotic machining, addressing the limitations caused by the compliance and low stiffness of industrial robots. The actuator utilizes a rotating flywheel, driven by an air-pressure turbine, to generate stabilizing gyroscopic moments, enhancing machining precision and stability. Key design features include a lightweight structure, a wireless optical angular speed sensor, and an electro-pneumatic proportional valve for flywheel speed control. A proportional-integral control algorithm, using accelerometer feedback, enables real-time adjustment of the gyroscopic moment to counteract vibrations effectively. Experimental validation demonstrated significant suppression of low-frequency vibrations, particularly at about 6 Hz, alongside reductions in higher-frequency structural vibrations. These results highlight the actuator’s ability to improve surface quality and machining stability while maintaining reliable performance across various conditions. This work shows the potential of gyroscopic spindle actuators to overcome vibration-induced challenges in robotic machining and offers a foundation for future advancements in robotic manufacturing systems.

针对工业机器人柔顺性和低刚度的局限性，提出了一种用于机器人加工中振动抑制的陀螺主轴执行器。驱动器采用旋转飞轮，由气压涡轮驱动，产生稳定的陀螺仪力矩，提高加工精度和稳定性。主要设计特点包括轻型结构、无线光学角速度传感器和用于飞轮速度控制的电-气比例阀。比例积分控制算法，利用加速度计反馈，能够实时调整陀螺仪力矩，有效地抵消振动。实验验证表明，在降低高频结构振动的同时，显著抑制了低频振动，特别是在6 Hz左右。这些结果突出了执行器提高表面质量和加工稳定性的能力，同时在各种条件下保持可靠的性能。这项工作显示了陀螺仪主轴执行器克服机器人加工中振动引起的挑战的潜力，并为机器人制造系统的未来发展奠定了基础。

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引用次数: 0