Pub Date : 2025-11-19DOI: 10.1016/j.precisioneng.2025.11.021
Christian Haider, Damian Senoner, Andreas Sinn, Adis Husanović, Benjamin Friedl, Georg Schitter
This paper presents a Stewart platform with hybrid reluctance-actuated struts to achieve six-degrees-of-freedom motion capability. Tailored hybrid reluctance actuators (HRAs) are integrated into a novel strut design to achieve axial force transmission to the Stewart platform’s end effector via flexure-based joints. Each actuator has a motion range of 1 mm, leading to a platform workspace of 1.34 mm along the vertical z-axis and 1.1 mm in x- and y-direction. The rotational range amounts to 0.66°/0.78° for tip/tilt motion. By implementation of a MIMO decoupling approach using canonical polyadic decomposition (CPD), position control bandwidths of up to 30 Hz are reached in the task space. The platform achieves millimeter stroke with sub-micrometer translational resolution (45 nm RMS), sub-microradian angular resolution (300 nrad RMS) and a bidirectional repeatability (1) of 0.15–0.32 µm and 3.5–4.8 µrad. The overall positioning accuracy (RMSE), quantified against external interferometric measurements, amounts to 1-2.3 µm in translation and 11–15 µrad in rotation.
{"title":"Hybrid reluctance-actuated Stewart platform for high-precision position control","authors":"Christian Haider, Damian Senoner, Andreas Sinn, Adis Husanović, Benjamin Friedl, Georg Schitter","doi":"10.1016/j.precisioneng.2025.11.021","DOIUrl":"10.1016/j.precisioneng.2025.11.021","url":null,"abstract":"<div><div>This paper presents a Stewart platform with hybrid reluctance-actuated struts to achieve six-degrees-of-freedom motion capability. Tailored hybrid reluctance actuators (HRAs) are integrated into a novel strut design to achieve axial force transmission to the Stewart platform’s end effector via flexure-based joints. Each actuator has a motion range of <span><math><mo>±</mo></math></span>1 mm, leading to a platform workspace of <span><math><mo>±</mo></math></span>1.34 mm along the vertical z-axis and <span><math><mo>±</mo></math></span>1.1 mm in x- and y-direction. The rotational range amounts to <span><math><mo>±</mo></math></span>0.66°/0.78° for tip/tilt motion. By implementation of a MIMO decoupling approach using canonical polyadic decomposition (CPD), position control bandwidths of up to 30 Hz are reached in the task space. The platform achieves millimeter stroke with sub-micrometer translational resolution (45 nm RMS), sub-microradian angular resolution (300 nrad RMS) and a bidirectional repeatability (1<span><math><mi>σ</mi></math></span>) of 0.15–0.32 µm and 3.5–4.8 µrad. The overall positioning accuracy (RMSE), quantified against external interferometric measurements, amounts to 1-2.3 µm in translation and 11–15 µrad in rotation.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"98 ","pages":"Pages 27-36"},"PeriodicalIF":3.7,"publicationDate":"2025-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618678","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}
Pub Date : 2025-11-17DOI: 10.1016/j.precisioneng.2025.11.018
Yulong Dai , Fanning Meng , Chunjing Shi , Can Wu , Chun Cao , Zeqiang Li , Zuochao Zhang
GCr15, a widely utilized high-carbon chromium bearing steel, is extensively employed in manufacturing bearing rings due to its excellent wear resistance and corrosion resistance. In aerospace applications where stringent surface roughness requirements are imposed on bearings, this study presents a novel polishing slurry comprising D-sorbitol, silica sol, H2O2, disodium EDTA, and benzotriazole (BTA) to achieve near-atomic-level polishing of GCr15 bearing steel within a defined parameter range. Under a 20 μm × 20 μm measurement area, the lowest reported areal surface roughness (Sa) value of 0.204 nm was attained, approaching atomic-scale smoothness. The polishing mechanism was investigated via Energy-Dispersive X-ray Spectroscopy (EDS), X-ray Photoelectron Spectroscopy (XPS) and Inductively Coupled Plasma Mass Spectrometry (ICP-MS), revealing that under alkaline conditions, H2O2 and disodium EDTA oxidize Fe and Cr to form chelate complexes such as [Fe(EDTA)] − and [Cr(EDTA)]-. These complexes synergize with the mechanical removal action of SiO2 abrasives to realize an ultra-smooth surface.
{"title":"Achieving near-atomic-level surface finish on GCr15 bearing steel via CMP: mechanisms and process optimization","authors":"Yulong Dai , Fanning Meng , Chunjing Shi , Can Wu , Chun Cao , Zeqiang Li , Zuochao Zhang","doi":"10.1016/j.precisioneng.2025.11.018","DOIUrl":"10.1016/j.precisioneng.2025.11.018","url":null,"abstract":"<div><div>GCr15, a widely utilized high-carbon chromium bearing steel, is extensively employed in manufacturing bearing rings due to its excellent wear resistance and corrosion resistance. In aerospace applications where stringent surface roughness requirements are imposed on bearings, this study presents a novel polishing slurry comprising D-sorbitol, silica sol, H<sub>2</sub>O<sub>2</sub>, disodium EDTA, and benzotriazole (BTA) to achieve near-atomic-level polishing of GCr15 bearing steel within a defined parameter range. Under a 20 μm × 20 μm measurement area, the lowest reported areal surface roughness (Sa) value of 0.204 nm was attained, approaching atomic-scale smoothness. The polishing mechanism was investigated via Energy-Dispersive X-ray Spectroscopy (EDS), X-ray Photoelectron Spectroscopy (XPS) and Inductively Coupled Plasma Mass Spectrometry (ICP-MS), revealing that under alkaline conditions, H<sub>2</sub>O<sub>2</sub> and disodium EDTA oxidize Fe and Cr to form chelate complexes such as [Fe(EDTA)] − and [Cr(EDTA)]<sup>-</sup>. These complexes synergize with the mechanical removal action of SiO<sub>2</sub> abrasives to realize an ultra-smooth surface.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 1019-1028"},"PeriodicalIF":3.7,"publicationDate":"2025-11-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145578688","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}
Pub Date : 2025-11-15DOI: 10.1016/j.precisioneng.2025.11.017
Soichi Ibaraki, Kandai Kawano
The accuracy of touch-trigger probing by a robotic manipulator is determined by the accuracy of the robot forward kinematic model to estimate the stylus sphere position from angular positions of rotary axes. While many past works employ a robot kinematic model only containing the Denavit-Hartenberg (DH) errors as error sources, this paper presents the application of a novel model, containing the angular positioning and radial error motions of all the rotary axes, to the robotic probing. In the probing of a straightedge, the experiments show that a large portion of a higher frequency component in the probed profiles is attributable to the angular positioning error motion of rotary axes. On the other hand, a lower frequency “waviness” component is attributable more to the DH errors. As a fundamental study, this paper targets the probing by a planar robot arm, as it has a simpler kinematics, with significantly less error parameters, than a six-axis robot.
{"title":"Error sources in touch-trigger probing by a planar robot arm","authors":"Soichi Ibaraki, Kandai Kawano","doi":"10.1016/j.precisioneng.2025.11.017","DOIUrl":"10.1016/j.precisioneng.2025.11.017","url":null,"abstract":"<div><div>The accuracy of touch-trigger probing by a robotic manipulator is determined by the accuracy of the robot forward kinematic model to estimate the stylus sphere position from angular positions of rotary axes. While many past works employ a robot kinematic model only containing the Denavit-Hartenberg (DH) errors as error sources, this paper presents the application of a novel model, containing the angular positioning and radial error motions of all the rotary axes, to the robotic probing. In the probing of a straightedge, the experiments show that a large portion of a higher frequency component in the probed profiles is attributable to the angular positioning error motion of rotary axes. On the other hand, a lower frequency “waviness” component is attributable more to the DH errors. As a fundamental study, this paper targets the probing by a planar robot arm, as it has a simpler kinematics, with significantly less error parameters, than a six-axis robot.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 997-1005"},"PeriodicalIF":3.7,"publicationDate":"2025-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145578687","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}
Pub Date : 2025-11-13DOI: 10.1016/j.precisioneng.2025.11.013
Lang Zou , Chen Luo , Gang Zhang , Yuanmin He , Qihang Zhang , Yijun Zhou
Efficient and precise automatic measurement is essential for evaluating the manufacturing accuracy of industrial components. The measurement network composed of multiple laser tracker measurement stations (LTMSs) as the foundation for achieving automated measurement of large-scale industrial components, it is particularly important to improve its measurement accuracy. However, the measurement accuracy of the measurement network, which is constructed according to the existing methods, often deviates from its optimal state. To address this, a high-precision construction method for laser tracker measurement network is developed. Firstly, the weight coefficient matrix based on the measurement errors of enhanced reference system points and the iterative optimization algorithm are used to improve the accuracy of the transformation parameters between adjacent LTMSs. Secondly, the optimal number of LTMSs is determined based on the principle of minimizing overall measurement errors for any two measurement points. Finally, the spatial position of each LTMS is optimized according to the principle of minimum measurement errors. The transformation parameters verification experiment and the simulation measurement experiment prove the effectiveness of the proposed method, which can significantly reduce the transformation errors and the overall measurement errors. The proposed method provides a valuable way for industries to improve the performance of automatic measurement of laser tracker measurement networks in real environment.
{"title":"High-precision construction method for laser tracker measurement network","authors":"Lang Zou , Chen Luo , Gang Zhang , Yuanmin He , Qihang Zhang , Yijun Zhou","doi":"10.1016/j.precisioneng.2025.11.013","DOIUrl":"10.1016/j.precisioneng.2025.11.013","url":null,"abstract":"<div><div>Efficient and precise automatic measurement is essential for evaluating the manufacturing accuracy of industrial components. The measurement network composed of multiple laser tracker measurement stations (LTMSs) as the foundation for achieving automated measurement of large-scale industrial components, it is particularly important to improve its measurement accuracy. However, the measurement accuracy of the measurement network, which is constructed according to the existing methods, often deviates from its optimal state. To address this, a high-precision construction method for laser tracker measurement network is developed. Firstly, the weight coefficient matrix based on the measurement errors of enhanced reference system points and the iterative optimization algorithm are used to improve the accuracy of the transformation parameters between adjacent LTMSs. Secondly, the optimal number of LTMSs is determined based on the principle of minimizing overall measurement errors for any two measurement points. Finally, the spatial position of each LTMS is optimized according to the principle of minimum measurement errors. The transformation parameters verification experiment and the simulation measurement experiment prove the effectiveness of the proposed method, which can significantly reduce the transformation errors and the overall measurement errors. The proposed method provides a valuable way for industries to improve the performance of automatic measurement of laser tracker measurement networks in real environment.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 1006-1018"},"PeriodicalIF":3.7,"publicationDate":"2025-11-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145578686","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}
Pub Date : 2025-11-13DOI: 10.1016/j.precisioneng.2025.11.016
Dongxiao Yan , Nian Duan , Tukun Li , Paul Bills , Leigh Fleming , Hui Huang
To achieve sustainable and efficient production of 4H-SiC wafers, this study proposes a two-step plasma-assisted polishing method, which combines the parallel plate dielectric barrier discharge (PP-DBD) plasma irradiation with mechanical polishing (MP) using soft abrasives: (1) parallel-plate dielectric barrier discharge (PP-DBD) plasma irradiation to soften the wafer surface, followed by, (2) soft abrasives MP to remove the modified layer and achieve high surface quality. Key processing parameters—electrode spacing, applied voltage, and irradiation duration—were systematically optimised to form a uniform modified layer approximately 35 nm thick. The modified surfaces were characterised using transmission electron microscopy (TEM) and ellipsometry. The process achieved a material removal rate (MRR) of 220 nm/h, reducing the polishing time required to reach the target surface roughness from 300 min to 15 min compared with soft abrasives MP. This two-step, chemical-free approach significantly improves both polishing efficiency and surface quality, offering a scalable and environmentally sustainable solution for ultra-precision finishing of 4H-SiC wafers.
{"title":"Hybrid assisted polishing technique for 4H-SiC wafers using parallel plate dielectric barrier discharge plasma and mechanical polishing","authors":"Dongxiao Yan , Nian Duan , Tukun Li , Paul Bills , Leigh Fleming , Hui Huang","doi":"10.1016/j.precisioneng.2025.11.016","DOIUrl":"10.1016/j.precisioneng.2025.11.016","url":null,"abstract":"<div><div>To achieve sustainable and efficient production of 4H-SiC wafers, this study proposes a two-step plasma-assisted polishing method, which combines the parallel plate dielectric barrier discharge (PP-DBD) plasma irradiation with mechanical polishing (MP) using soft abrasives: (1) parallel-plate dielectric barrier discharge (PP-DBD) plasma irradiation to soften the wafer surface, followed by, (2) soft abrasives MP to remove the modified layer and achieve high surface quality. Key processing parameters—electrode spacing, applied voltage, and irradiation duration—were systematically optimised to form a uniform modified layer approximately 35 nm thick. The modified surfaces were characterised using transmission electron microscopy (TEM) and ellipsometry. The process achieved a material removal rate (MRR) of 220 nm/h, reducing the polishing time required to reach the target surface roughness from 300 min to 15 min compared with soft abrasives MP. This two-step, chemical-free approach significantly improves both polishing efficiency and surface quality, offering a scalable and environmentally sustainable solution for ultra-precision finishing of 4H-SiC wafers.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 977-985"},"PeriodicalIF":3.7,"publicationDate":"2025-11-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145578684","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}
Pub Date : 2025-11-13DOI: 10.1016/j.precisioneng.2025.11.014
Desheng Gao , Xiaoguang Guo , Wanxue Zhang , Yu Pu , Zhiqiang Liu , Renke Kang , Zhigang Dong
This research proposes a combined strategy of ultrasonic assisted grinding and precision grinding to address the inherent conflict between processing efficiency and high surface accuracy. The grinding residual height model elucidates the impact of grinding wheel and process factors on residual height, establishing a correlation between surface shape accuracy and residual height. The combined process strategy is evaluated on an off-axis aspheric mirror with a diameter of 150 mm. The ultrasonic vibration frequency (25 kHz) and ultrasonic amplitude (1.7μm) were established. The surface shape accuracy PV = 9.560 μm, RMS = 2.442 μm, Ra = 0.124 μm. The total processing cycle is 15 h 35 min. The research findings indicate that ultrasonic assisted grinding offers significant advantages in processing hard and brittle materials.
{"title":"Aspheric mirror high-efficiency precision grinding strategy based on the residual height modeling","authors":"Desheng Gao , Xiaoguang Guo , Wanxue Zhang , Yu Pu , Zhiqiang Liu , Renke Kang , Zhigang Dong","doi":"10.1016/j.precisioneng.2025.11.014","DOIUrl":"10.1016/j.precisioneng.2025.11.014","url":null,"abstract":"<div><div>This research proposes a combined strategy of ultrasonic assisted grinding and precision grinding to address the inherent conflict between processing efficiency and high surface accuracy. The grinding residual height model elucidates the impact of grinding wheel and process factors on residual height, establishing a correlation between surface shape accuracy and residual height. The combined process strategy is evaluated on an off-axis aspheric mirror with a diameter of 150 mm. The ultrasonic vibration frequency (25 kHz) and ultrasonic amplitude (1.7μm) were established. The surface shape accuracy PV = 9.560 μm, RMS = 2.442 μm, Ra = 0.124 μm. The total processing cycle is 15 h 35 min. The research findings indicate that ultrasonic assisted grinding offers significant advantages in processing hard and brittle materials.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 1029-1048"},"PeriodicalIF":3.7,"publicationDate":"2025-11-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145578681","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}
Pub Date : 2025-11-12DOI: 10.1016/j.precisioneng.2025.11.010
Kai Egashira, Taiki Mizutani
The nibbling process is a method used to cut arbitrary features from thin sheets by continuously piercing partially overlapping holes to form slits. While laser processing is currently the dominant method for such cutting, nibbling offers several advantages, including lower operational costs and the absence of thermal effects on the workpiece. In microfabrication, laser processing has inherent limitations that present both technical and financial challenges. Therefore, this study developed a micro-nibbling method for fabricating microfeatures using a dieless punching technique, where the workpiece is supported from underneath by a backing material, eliminating the need for a die and die set assembly and enabling the practical use of micropunches. A punching device specifically designed for micropunches, fabricated from cemented tungsten carbide using electrical discharge machining, was employed with stainless steel sheets as the workpiece. Initial experiments used a 20 μm-diameter punch on a 5 μm-thick sheet, varying the punch feed pitch from 5 to 15 μm, and successfully produced slits at all pitches, demonstrating the feasibility of the method. Subsequently, punches with diameters below 10 μm were used on 3 μm-thick sheets with feed pitches ranging from 3 to 8 μm. Additionally, slit-and-space patterns were produced using a 5 μm-diameter punch on 2 μm-thick sheets, yielding slits approximately 5 μm wide with comparable spacing. Rotating the punch at 1000 min−1 significantly reduced the punch load compared with non-rotating punches. Finally, the fabrication of cut-out pieces, including a 120 μm square and a 300 μm-radius sector on 5 μm-thick sheets, demonstrated the versatility and applicability of the proposed micro-nibbling method.
{"title":"Development of micro-nibbling method based on dieless punching","authors":"Kai Egashira, Taiki Mizutani","doi":"10.1016/j.precisioneng.2025.11.010","DOIUrl":"10.1016/j.precisioneng.2025.11.010","url":null,"abstract":"<div><div>The nibbling process is a method used to cut arbitrary features from thin sheets by continuously piercing partially overlapping holes to form slits. While laser processing is currently the dominant method for such cutting, nibbling offers several advantages, including lower operational costs and the absence of thermal effects on the workpiece. In microfabrication, laser processing has inherent limitations that present both technical and financial challenges. Therefore, this study developed a micro-nibbling method for fabricating microfeatures using a dieless punching technique, where the workpiece is supported from underneath by a backing material, eliminating the need for a die and die set assembly and enabling the practical use of micropunches. A punching device specifically designed for micropunches, fabricated from cemented tungsten carbide using electrical discharge machining, was employed with stainless steel sheets as the workpiece. Initial experiments used a 20 μm-diameter punch on a 5 μm-thick sheet, varying the punch feed pitch from 5 to 15 μm, and successfully produced slits at all pitches, demonstrating the feasibility of the method. Subsequently, punches with diameters below 10 μm were used on 3 μm-thick sheets with feed pitches ranging from 3 to 8 μm. Additionally, slit-and-space patterns were produced using a 5 μm-diameter punch on 2 μm-thick sheets, yielding slits approximately 5 μm wide with comparable spacing. Rotating the punch at 1000 min<sup>−1</sup> significantly reduced the punch load compared with non-rotating punches. Finally, the fabrication of cut-out pieces, including a 120 μm square and a 300 μm-radius sector on 5 μm-thick sheets, demonstrated the versatility and applicability of the proposed micro-nibbling method.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 953-960"},"PeriodicalIF":3.7,"publicationDate":"2025-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145528426","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}
Pub Date : 2025-11-12DOI: 10.1016/j.precisioneng.2025.11.008
Zhang Yun , An Di , Ye Huan , Chen Zhitong , Cheng Geng , Liu Jingqing
To address the challenge of collaborative optimization between material removal efficiency and surface consistency caused by non-uniform machining allowances in the polishing of aero-engine blade leading/trailing edges, this paper proposes a trajectory planning method based on a removal model and a counter torus flexible polishing tool. By defining the counter torus flexible tool, a material removal model incorporating parameters such as curvature radius and preload is established through Hertz contact theory and orthogonal experimental data. Based on this model, a tool positioning coordinate system is constructed, and the tool posture is optimized by adjusting the yaw angle and rake angle to establish a trajectory optimization model with the goal of minimizing the average absolute deviation of cutting depth. Experiments show that when machining simple and complex blades with the counter torus flexible tool, the number of tool paths required is 9.8 % and 23.1 % of that of conventional convex tools, respectively. The surface roughness is better than Ra 0.4 μm, and the uniformity of material removal depth at the leading/trailing edges is significantly improved. This method provides theoretical and technical support for high-precision and high-efficiency polishing of aero-engine blade leading/trailing edges.
{"title":"Research on polishing trajectory planning method for leading/trailing edge based on polishing removal model of counter torus flexible tool","authors":"Zhang Yun , An Di , Ye Huan , Chen Zhitong , Cheng Geng , Liu Jingqing","doi":"10.1016/j.precisioneng.2025.11.008","DOIUrl":"10.1016/j.precisioneng.2025.11.008","url":null,"abstract":"<div><div>To address the challenge of collaborative optimization between material removal efficiency and surface consistency caused by non-uniform machining allowances in the polishing of aero-engine blade leading/trailing edges, this paper proposes a trajectory planning method based on a removal model and a counter torus flexible polishing tool. By defining the counter torus flexible tool, a material removal model incorporating parameters such as curvature radius and preload is established through Hertz contact theory and orthogonal experimental data. Based on this model, a tool positioning coordinate system is constructed, and the tool posture is optimized by adjusting the yaw angle and rake angle to establish a trajectory optimization model with the goal of minimizing the average absolute deviation of cutting depth. Experiments show that when machining simple and complex blades with the counter torus flexible tool, the number of tool paths required is 9.8 % and 23.1 % of that of conventional convex tools, respectively. The surface roughness is better than Ra 0.4 μm, and the uniformity of material removal depth at the leading/trailing edges is significantly improved. This method provides theoretical and technical support for high-precision and high-efficiency polishing of aero-engine blade leading/trailing edges.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 986-996"},"PeriodicalIF":3.7,"publicationDate":"2025-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145578685","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}
Pub Date : 2025-11-11DOI: 10.1016/j.precisioneng.2025.11.011
Li Zu , Zhenwen Cheng , Manxin Wang , Mingcai Xing , Guanlin Ren
The stroke error of planetary roller screw mechanism (PRSM) is one of the main indicators for evaluating the performances of PRSM. However, the variation law of stroke error of PRSM is currently unclear. Hence, this paper proposes the stroke error prediction model of PRSM. And the test bench of stroke error of PRSM is established to prove the presented model. The eccentric errors (EE) of screw and nut, pitch errors of screw, nut and roller are measured by the dial indicator and profilometer, respectively. The effects of EE of screw and nut, pitch errors of screw, nut and roller on the stroke error of PRSM are investigated. This investigation indicates that the stroke accuracy of PRSM can be improved through regulating the geometrical errors.
{"title":"Stroke error analysis of planetary roller screw mechanism with eccentric errors and pitch errors","authors":"Li Zu , Zhenwen Cheng , Manxin Wang , Mingcai Xing , Guanlin Ren","doi":"10.1016/j.precisioneng.2025.11.011","DOIUrl":"10.1016/j.precisioneng.2025.11.011","url":null,"abstract":"<div><div>The stroke error of planetary roller screw mechanism (PRSM) is one of the main indicators for evaluating the performances of PRSM. However, the variation law of stroke error of PRSM is currently unclear. Hence, this paper proposes the stroke error prediction model of PRSM. And the test bench of stroke error of PRSM is established to prove the presented model. The eccentric errors (EE) of screw and nut, pitch errors of screw, nut and roller are measured by the dial indicator and profilometer, respectively. The effects of EE of screw and nut, pitch errors of screw, nut and roller on the stroke error of PRSM are investigated. This investigation indicates that the stroke accuracy of PRSM can be improved through regulating the geometrical errors.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 925-935"},"PeriodicalIF":3.7,"publicationDate":"2025-11-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145528424","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}
Subsurface damages (SSDs) are inevitably produced during traditional abrasive machining processes of brittle materials. Such damages significantly impact the service performance and lifespan of these materials, which should be evaluated. This paper develops a method for predicting the subsurface crack depth based on nanoindentation tests. The method attempts to establish new relationships between the deformation zone depth and the median crack depth, with particular attention to the indenter shape, subsurface crack inclination, and material elastic recovery. To validate the method, diamond wire sawing experiments are conducted on a single-crystal silicon ingot, and then the subsurface morphologies and indentation behavior of the silicon wafers are analyzed. The result shows that the subsurface median cracks exhibit a certain inclination angle, ranging from 10.3° to 19.3°. There is a turning point or position for the elastic recovery, nominal contact modulus, and hardness versus the maximum indentation load curve. The experimental values of SSD depth fall within the range of theoretical ones. The relative error between the theoretical and experimental values of SSD depth is minimized when utilizing some newly established relationships in contrast to prior relationships. The theoretical values of SSD depth for the conical indenter, considering crack inclination and elastic recovery, align more closely with the experimental values. Using prior relationships, the minimum relative errors are 18.5 % (conical indenter) and 20.7 % (pyramidal indenter). With the newly established relationships, these errors reduce to 16.6 % and 18.8 %, respectively. This research presents a novel method for evaluating SSDs in abrasive-machined brittle materials.
{"title":"Prediction of subsurface crack depth during abrasive machining of brittle materials based on nanoindentation tests","authors":"Huapan Xiao , Shenxin Yin , Yilin Wu , Qingqing Huang , Sen Yin","doi":"10.1016/j.precisioneng.2025.11.012","DOIUrl":"10.1016/j.precisioneng.2025.11.012","url":null,"abstract":"<div><div>Subsurface damages (SSDs) are inevitably produced during traditional abrasive machining processes of brittle materials. Such damages significantly impact the service performance and lifespan of these materials, which should be evaluated. This paper develops a method for predicting the subsurface crack depth based on nanoindentation tests. The method attempts to establish new relationships between the deformation zone depth and the median crack depth, with particular attention to the indenter shape, subsurface crack inclination, and material elastic recovery. To validate the method, diamond wire sawing experiments are conducted on a single-crystal silicon ingot, and then the subsurface morphologies and indentation behavior of the silicon wafers are analyzed. The result shows that the subsurface median cracks exhibit a certain inclination angle, ranging from 10.3° to 19.3°. There is a turning point or position for the elastic recovery, nominal contact modulus, and hardness versus the maximum indentation load curve. The experimental values of SSD depth fall within the range of theoretical ones. The relative error between the theoretical and experimental values of SSD depth is minimized when utilizing some newly established relationships in contrast to prior relationships. The theoretical values of SSD depth for the conical indenter, considering crack inclination and elastic recovery, align more closely with the experimental values. Using prior relationships, the minimum relative errors are 18.5 % (conical indenter) and 20.7 % (pyramidal indenter). With the newly established relationships, these errors reduce to 16.6 % and 18.8 %, respectively. This research presents a novel method for evaluating SSDs in abrasive-machined brittle materials.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"97 ","pages":"Pages 936-952"},"PeriodicalIF":3.7,"publicationDate":"2025-11-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145528425","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}
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