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Parametric and theoretical study of hole quality in conventional micro-machining and rotary ultrasonic micro-machining of silicon
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-10 DOI: 10.1016/j.precisioneng.2025.01.008
Yunze Li , Zhijian Pei , Weilong Cong
Microhole machining for silicon is an essential process in the manufacturing of several semiconductor devices, such as solar panels, pressure and flow sensors, the stacking of micro-electromechanical systems, and complementary metal-oxide semiconductors. Due to the device miniaturization, there is a growing need for micro-machining on silicon wafers. Compared with the thermal machining processes for micro-drilling (such as laser machining), mechanical micro-machining processes can avoid the generation of heat-affected-zone, recast layers, and silicon oxidation. Conventional mechanical micro-machining (CμM) of brittle materials generates a higher cutting force and severe quality issues (such as cracking and edge chipping). To address the quality issues, drilling with rotary ultrasonic micro-machining (RUμM) has been proposed and applied. There are no reported investigations on comparisons of micro-machining quality in CμM and RUμM. In this study, the effects of ultrasonic vibration, tool diameter, and feed rate on cutting force and edge chipping were investigated experimentally. To explain machined hole quality (edge chipping) and cutting force, effects on indentation depth were also investigated. We developed the mechanistic models to describe the relationships between input variables and single abrasive indentation depth for both CμM and RUμM processes. Finally, the relationships among ultrasonic indentation, cutting force, and hole quality were established.
{"title":"Parametric and theoretical study of hole quality in conventional micro-machining and rotary ultrasonic micro-machining of silicon","authors":"Yunze Li ,&nbsp;Zhijian Pei ,&nbsp;Weilong Cong","doi":"10.1016/j.precisioneng.2025.01.008","DOIUrl":"10.1016/j.precisioneng.2025.01.008","url":null,"abstract":"<div><div>Microhole machining for silicon is an essential process in the manufacturing of several semiconductor devices, such as solar panels, pressure and flow sensors, the stacking of micro-electromechanical systems, and complementary metal-oxide semiconductors. Due to the device miniaturization, there is a growing need for micro-machining on silicon wafers. Compared with the thermal machining processes for micro-drilling (such as laser machining), mechanical micro-machining processes can avoid the generation of heat-affected-zone, recast layers, and silicon oxidation. Conventional mechanical micro-machining (CμM) of brittle materials generates a higher cutting force and severe quality issues (such as cracking and edge chipping). To address the quality issues, drilling with rotary ultrasonic micro-machining (RUμM) has been proposed and applied. There are no reported investigations on comparisons of micro-machining quality in CμM and RUμM. In this study, the effects of ultrasonic vibration, tool diameter, and feed rate on cutting force and edge chipping were investigated experimentally. To explain machined hole quality (edge chipping) and cutting force, effects on indentation depth were also investigated. We developed the mechanistic models to describe the relationships between input variables and single abrasive indentation depth for both CμM and RUμM processes. Finally, the relationships among ultrasonic indentation, cutting force, and hole quality were established.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 167-176"},"PeriodicalIF":3.5,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143369643","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}
引用次数: 0
Sensitivity study of parameters in a hybrid electrochemical-mechanical polishing process for 316L stainless steel
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-10 DOI: 10.1016/j.precisioneng.2025.01.007
Daniel Krzak , Florian Roy , Ferdinando Salvatore , Antoine Gidon , Stéphane Guerin , Joël Rech
The PEMEC process is a new polishing process designed for complex metal parts with high surface roughness. This new hybrid process has been developed by simultaneously coupling tribofinishing and electrochemical polishing. The PEMEC process improves surface roughness in just a few minutes, while preserving edge shape, and is based on a strong synergistic effect between abrasive and chemical mechanisms. To better understand this synergy, it is essential to know which parameters have the greatest influence on polishing results. To this end, it was decided to study the most influential parameters of the two processes combined in PEMEC: drag speed (tribofinishing) as well as temperature and voltage (electropolishing).
This article focusses on the influence of each of these parameters on the PEMEC process, using a multi-scale analysis that simultaneously considers surface roughness, edge geometry, and sample dimensions. For each of the three parameters, the various observable impacts on the sample are described and quantified. Analysis of the results showed that temperature and voltage have a considerable impact on the PEMEC process and are able to modify the mechanisms of the process, as well as material removal rate. In comparison, drag speed has a smaller influence on the process.
{"title":"Sensitivity study of parameters in a hybrid electrochemical-mechanical polishing process for 316L stainless steel","authors":"Daniel Krzak ,&nbsp;Florian Roy ,&nbsp;Ferdinando Salvatore ,&nbsp;Antoine Gidon ,&nbsp;Stéphane Guerin ,&nbsp;Joël Rech","doi":"10.1016/j.precisioneng.2025.01.007","DOIUrl":"10.1016/j.precisioneng.2025.01.007","url":null,"abstract":"<div><div>The PEMEC process is a new polishing process designed for complex metal parts with high surface roughness. This new hybrid process has been developed by simultaneously coupling tribofinishing and electrochemical polishing. The PEMEC process improves surface roughness in just a few minutes, while preserving edge shape, and is based on a strong synergistic effect between abrasive and chemical mechanisms. To better understand this synergy, it is essential to know which parameters have the greatest influence on polishing results. To this end, it was decided to study the most influential parameters of the two processes combined in PEMEC: drag speed (tribofinishing) as well as temperature and voltage (electropolishing).</div><div>This article focusses on the influence of each of these parameters on the PEMEC process, using a multi-scale analysis that simultaneously considers surface roughness, edge geometry, and sample dimensions. For each of the three parameters, the various observable impacts on the sample are described and quantified. Analysis of the results showed that temperature and voltage have a considerable impact on the PEMEC process and are able to modify the mechanisms of the process, as well as material removal rate. In comparison, drag speed has a smaller influence on the process.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 285-301"},"PeriodicalIF":3.5,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143286931","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}
引用次数: 0
Wear mechanisms of diamond tools and their material basis in machining iron-based materials
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-08 DOI: 10.1016/j.precisioneng.2025.01.004
Zejiang Xu , Guoqing Zhang , Jiabao Zhang , Zejia Huang , Wenqi Zhang , Minghua Pan
Diamond tools are widely used in ultra-precision machining due to their excellent physicochemical properties, enabling workpiece materials to achieve mirror surface quality. However, when machining iron-based materials, diamond tools are prone to graphitization due to electrochemistry reactions between carbon and iron atoms, this reduces the sharpness of the tool cutting edge, which further affects or even seriously damages the machined surface quality. Therefore, understanding the diamond tools wear mechanism and corresponding wear suppression methods is crucial for enhancing the machined surface quality. This paper reviews the wear mechanisms of diamond tools and their material basis in machining iron-based materials. Firstly, the paper reviews the affinity between iron and carbon atoms from the perspective of material basis and reviews the selection of diamond tool crystal plane orientations for machining iron-based materials. Secondly, this paper summarizes the wear mechanisms for diamond tools used in machining iron-based materials. Finally, aiming at the wear mechanism, the paper emphasizes suppression methods for diamond tool wear during machining iron-based materials. Through the comprehensive study of these aspects, this review combines the material basis and diamond tool wear mechanism, contributes to the suppression of diamond tool wear in ultra-precision machining of iron-based materials and the improvement of machined surface quality, and also provides theoretical support and reference for subsequent scholars to propose new schemes that may suppress the graphitization of diamond tools.
{"title":"Wear mechanisms of diamond tools and their material basis in machining iron-based materials","authors":"Zejiang Xu ,&nbsp;Guoqing Zhang ,&nbsp;Jiabao Zhang ,&nbsp;Zejia Huang ,&nbsp;Wenqi Zhang ,&nbsp;Minghua Pan","doi":"10.1016/j.precisioneng.2025.01.004","DOIUrl":"10.1016/j.precisioneng.2025.01.004","url":null,"abstract":"<div><div>Diamond tools are widely used in ultra-precision machining due to their excellent physicochemical properties, enabling workpiece materials to achieve mirror surface quality. However, when machining iron-based materials, diamond tools are prone to graphitization due to electrochemistry reactions between carbon and iron atoms, this reduces the sharpness of the tool cutting edge, which further affects or even seriously damages the machined surface quality. Therefore, understanding the diamond tools wear mechanism and corresponding wear suppression methods is crucial for enhancing the machined surface quality. This paper reviews the wear mechanisms of diamond tools and their material basis in machining iron-based materials. Firstly, the paper reviews the affinity between iron and carbon atoms from the perspective of material basis and reviews the selection of diamond tool crystal plane orientations for machining iron-based materials. Secondly, this paper summarizes the wear mechanisms for diamond tools used in machining iron-based materials. Finally, aiming at the wear mechanism, the paper emphasizes suppression methods for diamond tool wear during machining iron-based materials. Through the comprehensive study of these aspects, this review combines the material basis and diamond tool wear mechanism, contributes to the suppression of diamond tool wear in ultra-precision machining of iron-based materials and the improvement of machined surface quality, and also provides theoretical support and reference for subsequent scholars to propose new schemes that may suppress the graphitization of diamond tools.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 110-152"},"PeriodicalIF":3.5,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287291","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}
引用次数: 0
Effects from the stiffness and damping of O-rings on the stability and nonlinear dynamic characteristics of a rotor supported by flexible porous gas bearings
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-06 DOI: 10.1016/j.precisioneng.2025.01.003
Kang Zhang , Yu Huang , Wenjun Li , Hailong Cui , Youmin Rong , Kai Feng
In the field of high-speed rotating machinery, it is a common phenomenon that the rotor is liable to lose stability when rotating at high speeds. Installing a layer of damping structure between the bearing and the housing is a potential means to restrain the vibration of the rotor. In this article, it is useful to improve the stability of the rotor in the way of increasing the damping of the bearing by installing several O-rings on the porous air journal bearing (PAJB). The rotor-bearing test rig is set up to study the vibration of the rigid rotor supported by PAJBs with three types of O-rings mounted for different supply pressures. Moreover, a nonlinear numerical model is established to predict the rotor responses. The accuracy of the numerical model is verified by comparing the calculated results with the data tested by the above experiment. Based on the experimental and simulation results, the effects of the supply pressures, stiffness and damping of O-rings on the stability of the rotor-PAJB system are investigated. The influence of the stiffness and damping of O-rings on the nonlinear dynamic characteristics of the systems is further studied by expanding the parameter range of the numerical simulation, and the relevant laws are summarized. The results demonstrate that both the stiffness and damping of O-rings have significant influence on the stability of the rotor-PAJB system. When the stiffness of O-rings is in the unstable stiffness interval, the stability of the rotor at high speeds will decrease. Meanwhile, larger damping produces better stability. By both the experimental and theoretical studies, the investigation is expected to promote the development of turbomachinery towards higher speeds and better stability.
{"title":"Effects from the stiffness and damping of O-rings on the stability and nonlinear dynamic characteristics of a rotor supported by flexible porous gas bearings","authors":"Kang Zhang ,&nbsp;Yu Huang ,&nbsp;Wenjun Li ,&nbsp;Hailong Cui ,&nbsp;Youmin Rong ,&nbsp;Kai Feng","doi":"10.1016/j.precisioneng.2025.01.003","DOIUrl":"10.1016/j.precisioneng.2025.01.003","url":null,"abstract":"<div><div>In the field of high-speed rotating machinery, it is a common phenomenon that the rotor is liable to lose stability when rotating at high speeds. Installing a layer of damping structure between the bearing and the housing is a potential means to restrain the vibration of the rotor. In this article, it is useful to improve the stability of the rotor in the way of increasing the damping of the bearing by installing several O-rings on the porous air journal bearing (PAJB). The rotor-bearing test rig is set up to study the vibration of the rigid rotor supported by PAJBs with three types of O-rings mounted for different supply pressures. Moreover, a nonlinear numerical model is established to predict the rotor responses. The accuracy of the numerical model is verified by comparing the calculated results with the data tested by the above experiment. Based on the experimental and simulation results, the effects of the supply pressures, stiffness and damping of O-rings on the stability of the rotor-PAJB system are investigated. The influence of the stiffness and damping of O-rings on the nonlinear dynamic characteristics of the systems is further studied by expanding the parameter range of the numerical simulation, and the relevant laws are summarized. The results demonstrate that both the stiffness and damping of O-rings have significant influence on the stability of the rotor-PAJB system. When the stiffness of O-rings is in the unstable stiffness interval, the stability of the rotor at high speeds will decrease. Meanwhile, larger damping produces better stability. By both the experimental and theoretical studies, the investigation is expected to promote the development of turbomachinery towards higher speeds and better stability.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 153-166"},"PeriodicalIF":3.5,"publicationDate":"2025-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287498","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}
引用次数: 0
Surface microstructure design and validation of flexible interventional guidewires: A comprehensive comparative study
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-04 DOI: 10.1016/j.precisioneng.2025.01.002
Pan Li , Xue Zhang , Jing Feng , Chunqing Yu , Cunman Liang
The intricate and narrow vascular networks present significant challenges for the compliance, flexibility, and maximum bending capabilities of interventional instruments. By focusing on the constrained bending capacity of guidewires in vascular procedures, the research delves into the surface microstructure design of flexible interventional guidewires to enhance their bending angles. This advancement facilitates smooth interventional procedures within limited workspaces. The research investigates how various structural size parameters of the surface microstructure affect the maximum bending capability of interventional guidewires. It encompasses the design and manufacture of four types of flexible interventional guidewires featuring rectangular, triangular, arc-shaped, and concave-pit-shaped microstructures. A theoretical model for guidewire bending angles is established, and through theoretical numerical analysis, the correlations between different microstructures, microstructural size parameters, and bending angles are elucidated. The study examines the bending characteristics of the four microstructured flexible interventional guidewires under tendon stretching displacement. Simulation analysis is employed to assess the influence of microstructural size parameters on the bending angles of the guidewires, confirming that guidewires with concave-pit-shaped microstructures can achieve greater bending angles, thereby enhancing their bending capabilities. An experimental setup is arranged to explore the bendable angles of the flexible interventional guidewires with the four types of microstructures. Furthermore, experiments on the interactive compliance between the microstructured flexible interventional guidewires and blood vessels are conducted to validate the guidewires’ deformation capabilities. The study affirms that the flexible interventional guidewire with concave-pit-shaped microstructures displays a greater bending angle. Specifically, the concave-pit-shaped microstructured flexible interventional guidewire, measuring 50 mm in length, can achieve a bending angle of 195° when subjected to a tendon stretching displacement of 4 mm, enabling successful interventions in intricate and narrow vascular networks like those encountered in heart/brain vasculature.
{"title":"Surface microstructure design and validation of flexible interventional guidewires: A comprehensive comparative study","authors":"Pan Li ,&nbsp;Xue Zhang ,&nbsp;Jing Feng ,&nbsp;Chunqing Yu ,&nbsp;Cunman Liang","doi":"10.1016/j.precisioneng.2025.01.002","DOIUrl":"10.1016/j.precisioneng.2025.01.002","url":null,"abstract":"<div><div>The intricate and narrow vascular networks present significant challenges for the compliance, flexibility, and maximum bending capabilities of interventional instruments. By focusing on the constrained bending capacity of guidewires in vascular procedures, the research delves into the surface microstructure design of flexible interventional guidewires to enhance their bending angles. This advancement facilitates smooth interventional procedures within limited workspaces. The research investigates how various structural size parameters of the surface microstructure affect the maximum bending capability of interventional guidewires. It encompasses the design and manufacture of four types of flexible interventional guidewires featuring rectangular, triangular, arc-shaped, and concave-pit-shaped microstructures. A theoretical model for guidewire bending angles is established, and through theoretical numerical analysis, the correlations between different microstructures, microstructural size parameters, and bending angles are elucidated. The study examines the bending characteristics of the four microstructured flexible interventional guidewires under tendon stretching displacement. Simulation analysis is employed to assess the influence of microstructural size parameters on the bending angles of the guidewires, confirming that guidewires with concave-pit-shaped microstructures can achieve greater bending angles, thereby enhancing their bending capabilities. An experimental setup is arranged to explore the bendable angles of the flexible interventional guidewires with the four types of microstructures. Furthermore, experiments on the interactive compliance between the microstructured flexible interventional guidewires and blood vessels are conducted to validate the guidewires’ deformation capabilities. The study affirms that the flexible interventional guidewire with concave-pit-shaped microstructures displays a greater bending angle. Specifically, the concave-pit-shaped microstructured flexible interventional guidewire, measuring 50 mm in length, can achieve a bending angle of 195° when subjected to a tendon stretching displacement of 4 mm, enabling successful interventions in intricate and narrow vascular networks like those encountered in heart/brain vasculature.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 70-86"},"PeriodicalIF":3.5,"publicationDate":"2025-01-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143287494","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}
引用次数: 0
A two-stage collision detection method of a multi-axis CNC machine tool based on bounding box and basic primitive
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-03 DOI: 10.1016/j.precisioneng.2025.01.001
Changjun Wu , Piaoyang Zhao , Qiaohua Wang , Guoyong Ye , Zhifeng Liu , Ri Pan
A fast and accurate two-stage collision detection method is proposed to ensure the normal processing of multi-axis CNC machine tools (MACMT) and avoid collision between the tool and the workpiece. Taking the machining of complex curved parts using a large gantry milling machine as an example, the motion relationship between the key components of the machine tool and the collision detection model are described in detail. Then, collision detection is performed on CNC machining through grading. In the first stage, the repeated projection method quickly eliminates long-distance non-intersecting collision detection. In the second stage, in order to further accurately detect, a hierarchical bounding box tree is constructed to divide the bounding boxes into layers and traverse the intersection states of each node layer by layer. A point set determination method is proposed for the basic primitive of leaf nodes to perform the most accurate collision detection. Finally, accuracy testing and real-time experimental verification are conducted in the self-developed MACMT virtual simulation system. The experimental results show that the proposed method can meet the requirements of accuracy and real-time performance. The lowest running frame rate of the proposed method is 89.1 FPS, and the average frame rate is 117.3 FPS. The detection efficiency is improved by 28.3 %, 12.9 %, 10.6 % and 9.8 % compared to traditional methods and other reference methods, respectively. Therefore, the method proposed in this paper can perform collision detection faster and more accurately, avoiding economic losses and ensuring personal safety.
{"title":"A two-stage collision detection method of a multi-axis CNC machine tool based on bounding box and basic primitive","authors":"Changjun Wu ,&nbsp;Piaoyang Zhao ,&nbsp;Qiaohua Wang ,&nbsp;Guoyong Ye ,&nbsp;Zhifeng Liu ,&nbsp;Ri Pan","doi":"10.1016/j.precisioneng.2025.01.001","DOIUrl":"10.1016/j.precisioneng.2025.01.001","url":null,"abstract":"<div><div>A fast and accurate two-stage collision detection method is proposed to ensure the normal processing of multi-axis CNC machine tools (MACMT) and avoid collision between the tool and the workpiece. Taking the machining of complex curved parts using a large gantry milling machine as an example, the motion relationship between the key components of the machine tool and the collision detection model are described in detail. Then, collision detection is performed on CNC machining through grading. In the first stage, the repeated projection method quickly eliminates long-distance non-intersecting collision detection. In the second stage, in order to further accurately detect, a hierarchical bounding box tree is constructed to divide the bounding boxes into layers and traverse the intersection states of each node layer by layer. A point set determination method is proposed for the basic primitive of leaf nodes to perform the most accurate collision detection. Finally, accuracy testing and real-time experimental verification are conducted in the self-developed MACMT virtual simulation system. The experimental results show that the proposed method can meet the requirements of accuracy and real-time performance. The lowest running frame rate of the proposed method is 89.1 FPS, and the average frame rate is 117.3 FPS. The detection efficiency is improved by 28.3 %, 12.9 %, 10.6 % and 9.8 % compared to traditional methods and other reference methods, respectively. Therefore, the method proposed in this paper can perform collision detection faster and more accurately, avoiding economic losses and ensuring personal safety.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"93 ","pages":"Pages 177-191"},"PeriodicalIF":3.5,"publicationDate":"2025-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143286920","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}
引用次数: 0
Glass thickness testing using Fizeau interferometer with suppression of environmental factors
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-01-02 DOI: 10.1016/j.precisioneng.2024.12.017
Jurim Jeon , Yangjin Kim , Yusuke Ito , Naohiko Sugita , Kenichi Hibino
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 Z-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.
{"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}
引用次数: 0
Surrogate model-based tool trajectory modification for ultra-precision tool servo diamond turning
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2024-12-31 DOI: 10.1016/j.precisioneng.2024.12.016
Hao Wu , YiXuan Meng , ZhiYang Zhao , ZhiWei Zhu , MingJun Ren , XinQuan Zhang , LiMin Zhu
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.
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引用次数: 0
Single-point synthesis of compliant mechanisms
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2024-12-30 DOI: 10.1016/j.precisioneng.2024.12.012
O. Sorgonà , O. Giannini , M. Verotti
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 point compliance synthesis 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.
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引用次数: 0
Enhancing image processing in single-camera two-wavelength imaging pyrometry for advanced in-situ melt pool measurement in laser powder bed fusion
IF 3.5 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2024-12-26 DOI: 10.1016/j.precisioneng.2024.12.013
Md Jahangir Alam, Haolin Zhang, Xiayun Zhao
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 <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.
{"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}
引用次数: 0
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Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology
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