Pub Date : 2026-05-01Epub Date: 2026-01-13DOI: 10.1016/j.precisioneng.2026.01.016
Zhao Han , Xu Han , Xiaolong Fang
Wire electrochemical machining (WECM) offers a promising solution for processing high-strength, high-hardness materials for aeroengine components. However, scattered corrosion and nonconcentrated electric fields hamper the process. In mitigation, pulse dynamic WECM (PD-WECM) has been proposed to optimize electric field distribution during cutting, significantly reducing slit width while achieving superior surface quality. This method involves categorizing the surface of the rotating electrode into active (work) and inactive (non-work) areas from a circumferential perspective. A chopping system is employed to synchronize power with work-area alignment, thereby concentrating the electric field and enhancing the mass transfer using wedged electrodes with insulating coatings. The chopping system reduces surface roughness to 0.59 μm, a 43 % decrease, and the wedged electrodes minimize slit width by 401 μm (17 %) compared to the result machined by circular electrode without the chopping system, thus enhancing mass transfer efficiency. Compared with continuous-electric-field WECM, our chopping technique is superior. Under conditions involving a 180° power-on angle using wedged electrodes with insulating coatings, we stabilized the slit sidewall roughness at ∼0.254 μm and maintained a slit width of ∼1.3 mm.
{"title":"Precision pulse dynamics wire electrochemical machining with structured electrodes","authors":"Zhao Han , Xu Han , Xiaolong Fang","doi":"10.1016/j.precisioneng.2026.01.016","DOIUrl":"10.1016/j.precisioneng.2026.01.016","url":null,"abstract":"<div><div>Wire electrochemical machining (WECM) offers a promising solution for processing high-strength, high-hardness materials for aeroengine components. However, scattered corrosion and nonconcentrated electric fields hamper the process. In mitigation, pulse dynamic WECM (PD-WECM) has been proposed to optimize electric field distribution during cutting, significantly reducing slit width while achieving superior surface quality. This method involves categorizing the surface of the rotating electrode into active (work) and inactive (non-work) areas from a circumferential perspective. A chopping system is employed to synchronize power with work-area alignment, thereby concentrating the electric field and enhancing the mass transfer using wedged electrodes with insulating coatings. The chopping system reduces surface roughness to 0.59 μm, a 43 % decrease, and the wedged electrodes minimize slit width by 401 μm (17 %) compared to the result machined by circular electrode without the chopping system, thus enhancing mass transfer efficiency. Compared with continuous-electric-field WECM, our chopping technique is superior. Under conditions involving a 180° power-on angle using wedged electrodes with insulating coatings, we stabilized the slit sidewall roughness at ∼0.254 μm and maintained a slit width of ∼1.3 mm.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 258-269"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023458","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 : 2026-05-01Epub Date: 2026-01-16DOI: 10.1016/j.precisioneng.2026.01.017
Yanliang Li , Baojie Yu , Weiye Hu , Tao Yang , Xiaoyun Hu , Yongbin Zeng
To improve the surface quality of internal channels in AlMgScZr alloy parts fabricated by laser powder bed fusion (LPBF), this study proposes an innovative hybrid process termed free abrasive assisted electrochemical polishing (FAECP), which synergistically combines electrochemical dissolution with free abrasive erosion. The concentration and velocity distribution of free abrasives within the interelectrode gap were simulated, and the synergistic effects between electrochemical dissolution and abrasive erosion during the FAECP were experimentally investigated. The results demonstrate that abrasive erosion effectively removes passive film and adhered products at surface peaks, thereby enhancing localized dissolution rates and mitigating non-uniform dissolution of the anode material. Concurrently, electrochemical dissolution softens the surface metallic layer, facilitating more efficient direct material removal by abrasive erosion. Compared to conventional electrochemical polishing (ECP), FAECP significantly improves both surface quality and polishing efficiency. Furthermore, the curved channels with an inner diameter of 5 mm were polished using a custom flexible tool electrode, the semi-welded particles and surface texture were completely removed, and the surface roughness Sa was reduced from 7.35-16.72 μm to 1.30–2.03 μm and the thickness loss was 180 μm.
{"title":"Investigation on surface quality improvement of laser powder bed fusion-fabricated internal channels via free abrasive assisted electrochemical polishing","authors":"Yanliang Li , Baojie Yu , Weiye Hu , Tao Yang , Xiaoyun Hu , Yongbin Zeng","doi":"10.1016/j.precisioneng.2026.01.017","DOIUrl":"10.1016/j.precisioneng.2026.01.017","url":null,"abstract":"<div><div>To improve the surface quality of internal channels in AlMgScZr alloy parts fabricated by laser powder bed fusion (LPBF), this study proposes an innovative hybrid process termed free abrasive assisted electrochemical polishing (FAECP), which synergistically combines electrochemical dissolution with free abrasive erosion. The concentration and velocity distribution of free abrasives within the interelectrode gap were simulated, and the synergistic effects between electrochemical dissolution and abrasive erosion during the FAECP were experimentally investigated. The results demonstrate that abrasive erosion effectively removes passive film and adhered products at surface peaks, thereby enhancing localized dissolution rates and mitigating non-uniform dissolution of the anode material. Concurrently, electrochemical dissolution softens the surface metallic layer, facilitating more efficient direct material removal by abrasive erosion. Compared to conventional electrochemical polishing (ECP), FAECP significantly improves both surface quality and polishing efficiency. Furthermore, the curved channels with an inner diameter of 5 mm were polished using a custom flexible tool electrode, the semi-welded particles and surface texture were completely removed, and the surface roughness Sa was reduced from 7.35-16.72 μm to 1.30–2.03 μm and the thickness loss was 180 μm.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 316-328"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023462","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}
Since the discovery of the self-cleaning property of lotus leaves, superhydrophobic surfaces have attracted significant attention due to their great potential in various engineering applications, including self-cleaning, enhanced heat transfer, antifouling, antibacterial, anti-icing, and droplet manipulation. However, their structural fragility continues to limit practical implementation. In recent years, remarkable progress has been made in developing mechanically robust superhydrophobic surfaces, covering aspects such as wetting theory, structured surface design, and advanced fabrication techniques. Nevertheless, a systematic review of these recent achievements is still lacking, which is crucial for providing new insights and guiding future research. Therefore, this paper comprehensively reviews recent advances in four key areas—wetting theory, robust superhydrophobic surface design strategies, advanced fabrication techniques, and testing methodologies—aiming to identify potential future research directions and offer new perspectives for the development of superhydrophobic surfaces.
{"title":"Advances on the mechanical robustness of superhydrophobic surfaces: Strategies, fabrication, and test","authors":"Douwei Liu, Wenbin Zhong, Wenhan Zeng, Xiangqian Jiang","doi":"10.1016/j.precisioneng.2026.01.006","DOIUrl":"10.1016/j.precisioneng.2026.01.006","url":null,"abstract":"<div><div>Since the discovery of the self-cleaning property of lotus leaves, superhydrophobic surfaces have attracted significant attention due to their great potential in various engineering applications, including self-cleaning, enhanced heat transfer, antifouling, antibacterial, anti-icing, and droplet manipulation. However, their structural fragility continues to limit practical implementation. In recent years, remarkable progress has been made in developing mechanically robust superhydrophobic surfaces, covering aspects such as wetting theory, structured surface design, and advanced fabrication techniques. Nevertheless, a systematic review of these recent achievements is still lacking, which is crucial for providing new insights and guiding future research. Therefore, this paper comprehensively reviews recent advances in four key areas—wetting theory, robust superhydrophobic surface design strategies, advanced fabrication techniques, and testing methodologies—aiming to identify potential future research directions and offer new perspectives for the development of superhydrophobic surfaces.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 186-213"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145978559","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}
Piezoelectric actuators (PEAs) are critical in precision motion applications due to their high precision and fast response. Existing control methods for PEAs rely heavily on the accurate model integrated in the controllers to realize the precision motion tracking. However, complicated dynamics and inherent hysteresis nonlinearity bring challenges in modeling and identification. The accompanying model uncertainties bring difficulties for the rapid convergence of the tracking error and precision motion tracking of PEAs in the application. To overcome these limitations, this paper proposes an adaptive neural network fixed-time control (ANNFTC) scheme. The ANNFTC integrates the backstepping method and online neural network compensation, both designed according to the practical fixed-time stability. Unlike the fixed-time control (FTC) and related works, ANNFTC requires no prior knowledge of hysteresis while ensuring robustness to external disturbance and model uncertainties, including unmodeled dynamics and hysteresis nonlinearity. Rigorous proof of practical fixed-time convergence for the tracking error is provided, along with comprehensive experimental validation conducted on a PEA. The experimental campaign encompasses reference tracking across frequencies ranging from 1 to 10 Hz and peak-to-peak amplitudes from 1 to 9 m, as well as hybrid-frequency sinusoidal tracking in the presence of input disturbances. Experimental results show that compared to other tested FTCs, ANNFTC achieves better tracking accuracy and more rapid convergence time of tracking error under different initial states, the existence of model uncertainties, and the external disturbance.
{"title":"Adaptive neural network fixed-time control of piezoelectric actuator for precision motion tracking","authors":"Yunzhi Zhang , Zhao Feng , Jie Ling , Chenyang Ding","doi":"10.1016/j.precisioneng.2026.01.015","DOIUrl":"10.1016/j.precisioneng.2026.01.015","url":null,"abstract":"<div><div>Piezoelectric actuators (PEAs) are critical in precision motion applications due to their high precision and fast response. Existing control methods for PEAs rely heavily on the accurate model integrated in the controllers to realize the precision motion tracking. However, complicated dynamics and inherent hysteresis nonlinearity bring challenges in modeling and identification. The accompanying model uncertainties bring difficulties for the rapid convergence of the tracking error and precision motion tracking of PEAs in the application. To overcome these limitations, this paper proposes an adaptive neural network fixed-time control (ANNFTC) scheme. The ANNFTC integrates the backstepping method and online neural network compensation, both designed according to the practical fixed-time stability. Unlike the fixed-time control (FTC) and related works, ANNFTC requires no prior knowledge of hysteresis while ensuring robustness to external disturbance and model uncertainties, including unmodeled dynamics and hysteresis nonlinearity. Rigorous proof of practical fixed-time convergence for the tracking error is provided, along with comprehensive experimental validation conducted on a PEA. The experimental campaign encompasses reference tracking across frequencies ranging from 1 to 10 Hz and peak-to-peak amplitudes from 1 to 9 <span><math><mi>μ</mi></math></span>m, as well as hybrid-frequency sinusoidal tracking in the presence of input disturbances. Experimental results show that compared to other tested FTCs, ANNFTC achieves better tracking accuracy and more rapid convergence time of tracking error under different initial states, the existence of model uncertainties, and the external disturbance.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 246-257"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145978558","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 : 2026-05-01Epub Date: 2026-01-03DOI: 10.1016/j.precisioneng.2026.01.007
Ning Feng, Yaqian Wang, Liqin Wang, Yulin Liu
The microscopic morphology of rolling bearing raceways (main load surface MLS) governs tribological performance under extreme conditions, yet conventional roughness parameters fail to characterize cross-scale features. This study proposes a dual-parameter method integrating fractal dimension D (via power spectral density analysis) and spectral width Δα (via multifractal detrended fluctuation analysis) to evaluate surface topography. Results show a negative correlation between D and bearing precision while Δα discriminates surface variations within the same grade. The synergistic D–Δα model enables comprehensive surface characterization by combining global complexity and local heterogeneity, providing a quantitative framework for precision manufacturing and reliability assessment of bearings.
{"title":"Relationship between machining accuracy and fractal dimension of rolling bearing raceway surfaces: A spectral bandwidth-driven surface quality evaluation method","authors":"Ning Feng, Yaqian Wang, Liqin Wang, Yulin Liu","doi":"10.1016/j.precisioneng.2026.01.007","DOIUrl":"10.1016/j.precisioneng.2026.01.007","url":null,"abstract":"<div><div>The microscopic morphology of rolling bearing raceways (main load surface MLS) governs tribological performance under extreme conditions, yet conventional roughness parameters fail to characterize cross-scale features. This study proposes a dual-parameter method integrating fractal dimension <strong><em>D</em></strong> (via power spectral density analysis) and spectral width Δα (via multifractal detrended fluctuation analysis) to evaluate surface topography. Results show a negative correlation between <strong><em>D</em></strong> and bearing precision while <strong><em>Δα</em></strong> discriminates surface variations within the same grade. The synergistic <strong><em>D</em></strong>–<strong><em>Δα</em></strong> model enables comprehensive surface characterization by combining global complexity and local heterogeneity, providing a quantitative framework for precision manufacturing and reliability assessment of bearings.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 78-88"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928258","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 : 2026-05-01Epub Date: 2026-01-19DOI: 10.1016/j.precisioneng.2026.01.019
Kanglin Pei , Jun Yi , Bibing Xiao , Hui Deng , Bing Chen
To address the challenges of non-uniform dissolution, insufficient flattening efficiency, and defect inheritance in conventional electrochemical polishing (ECP), this study proposes a constrained-electrolyte selective electrochemical polishing (CESECP) method employing a porous ceramic plate (PCP). The method utilizes a high-flatness PCP to confine the electrolyte into a uniform liquid film and incorporates a dynamic planetary motion mechanism to achieve efficient surface flattening. The surface-leveling capability and material removal mechanisms during electrochemical polishing under electrolyte-constrained conditions were investigated. Experimental results demonstrate that CESECP effectively mitigates surface defects and reduces workpiece surface irregularities, with the improvement efficiency governed by liquid film thickness. A nonlinear relationship model between liquid film thickness and the average pore size of the PCP was established based on Jurin's law and capillary dynamics, revealing the unimodal functional behavior of liquid film thickness. This model clarifies the influence mechanism of liquid film thickness on surface flattening quality, providing a theoretical foundation for optimizing key process parameters, particularly in balancing liquid film uniformity and material removal rate.
{"title":"Constrained electrolyte selective electrochemical polishing with porous ceramic plates: Mechanism of material removal","authors":"Kanglin Pei , Jun Yi , Bibing Xiao , Hui Deng , Bing Chen","doi":"10.1016/j.precisioneng.2026.01.019","DOIUrl":"10.1016/j.precisioneng.2026.01.019","url":null,"abstract":"<div><div>To address the challenges of non-uniform dissolution, insufficient flattening efficiency, and defect inheritance in conventional electrochemical polishing (ECP), this study proposes a constrained-electrolyte selective electrochemical polishing (CESECP) method employing a porous ceramic plate (PCP). The method utilizes a high-flatness PCP to confine the electrolyte into a uniform liquid film and incorporates a dynamic planetary motion mechanism to achieve efficient surface flattening. The surface-leveling capability and material removal mechanisms during electrochemical polishing under electrolyte-constrained conditions were investigated. Experimental results demonstrate that CESECP effectively mitigates surface defects and reduces workpiece surface irregularities, with the improvement efficiency governed by liquid film thickness. A nonlinear relationship model between liquid film thickness and the average pore size of the PCP was established based on Jurin's law and capillary dynamics, revealing the unimodal functional behavior of liquid film thickness. This model clarifies the influence mechanism of liquid film thickness on surface flattening quality, providing a theoretical foundation for optimizing key process parameters, particularly in balancing liquid film uniformity and material removal rate.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 294-315"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023461","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 : 2026-05-01Epub Date: 2025-12-20DOI: 10.1016/j.precisioneng.2025.12.015
Yuan Liu, Jingru Wang, Haojie Xia, Jin Zhang, Weishi Li
Ball bars are a type of length artifacts generally used in the performance verification of coordinate measuring machines. This paper presents a one-dimensional measuring machine (1-DMM) for calibrating the length of a ball bar, proposing a method for initializing the 1-DMM with two uncalibrated ball bars. The length of the ball bar calibrated with the 1-DMM is directly traceable to the laser wavelength. The 1-DMM is designed according to Abbe’s principle, and the measurement range of the proposed 1-DMM is from to , with expanded uncertainty of , where is given in meters. When measuring a ball bar with a length longer than , the uncertainty of the proposed 1-DMM is smaller than the expanded uncertainty of the existing 1-DMMs and the M48 CMM of NIST.
{"title":"A self-initialized one-dimensional measuring machine for calibrating the length of a ball bar","authors":"Yuan Liu, Jingru Wang, Haojie Xia, Jin Zhang, Weishi Li","doi":"10.1016/j.precisioneng.2025.12.015","DOIUrl":"10.1016/j.precisioneng.2025.12.015","url":null,"abstract":"<div><div>Ball bars are a type of length artifacts generally used in the performance verification of coordinate measuring machines. This paper presents a one-dimensional measuring machine (1-DMM) for calibrating the length of a ball bar, proposing a method for initializing the 1-DMM with two uncalibrated ball bars. The length of the ball bar calibrated with the 1-DMM is directly traceable to the laser wavelength. The 1-DMM is designed according to Abbe’s principle, and the measurement range of the proposed 1-DMM is from <span><math><mrow><mn>200</mn><mspace></mspace><mi>mm</mi></mrow></math></span> to <span><math><mrow><mn>2000</mn><mspace></mspace><mi>mm</mi></mrow></math></span>, with expanded uncertainty of <span><math><mrow><msqrt><mrow><mn>0</mn><mo>.</mo><mn>23</mn><msup><mrow><mi>L</mi></mrow><mrow><mn>2</mn></mrow></msup><mo>−</mo><mn>0</mn><mo>.</mo><mn>85</mn><mi>L</mi><mo>+</mo><mn>1</mn><mo>.</mo><mn>61</mn></mrow></msqrt><mi>μ</mi><mi>m</mi></mrow></math></span>, where <span><math><mi>L</mi></math></span> is given in meters. When measuring a ball bar with a length longer than <span><math><mrow><mn>1</mn><mo>.</mo><mn>1</mn><mi>m</mi></mrow></math></span>, the uncertainty of the proposed 1-DMM is smaller than the expanded uncertainty of the existing 1-DMMs and the M48 CMM of NIST.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 12-22"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145886523","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 : 2026-05-01Epub Date: 2026-01-13DOI: 10.1016/j.precisioneng.2026.01.013
Ganyu Chen , Yupeng Xiong , Cheng Huang , Yang Ou , Jiafu Zhou , Yifan Dai
High-power fiber lasers are crucial for defense and industrial applications owing to their superior energy-conversion efficiency and beam quality. However, a fiber laser usually exhibits a Gaussian distribution of the optical intensity mode. This decreases the beam energy utilization efficiency and increases the laser damage probability for the optics in high-power laser systems. Therefore, this study presents the design and fabrication of a novel integrated dual-aspheric beam shaper for transforming the Gaussian beam of high-power fiber lasers into a collimated flat-top profile while preserving the phase distribution with a high fill factor. Addressing the manufacturing challenges of the small-aperture, steeply curved of the shaper and the hard-to-machine characteristics of fused silica, this research employs elliptical ultrasonic vibration cutting (EUVC) technology as a low-damage processing method for fused silica beam shapers manufacturing. Kinematic analysis confirms that the periodic tool-workpiece separation in EUVC reduces cutting forces. Subsurface damage (SSD) detection experiments demonstrate a 60 % reduction in SSD compared to conventional ultraprecision cutting. Analysis indicates that discontinuous tool-workpiece contact suppresses micro-crack propagation. Laser shaping experiments validate that the EUVC fabricated shaper achieved controlling the intensity distribution of the fiber laser into flat profiles and realized a far-field energy concentration of 50.19 %, a near-field uniformity of 83.44 % and a laser-induced damage threshold (LIDT) of 10 kW/cm2, confirming its significant potential for high-power fiber laser shaping.
{"title":"A novel exploration of low damage elliptical ultrasonic vibration assisted cutting method for high-power fiber laser beam shapers","authors":"Ganyu Chen , Yupeng Xiong , Cheng Huang , Yang Ou , Jiafu Zhou , Yifan Dai","doi":"10.1016/j.precisioneng.2026.01.013","DOIUrl":"10.1016/j.precisioneng.2026.01.013","url":null,"abstract":"<div><div>High-power fiber lasers are crucial for defense and industrial applications owing to their superior energy-conversion efficiency and beam quality. However, a fiber laser usually exhibits a Gaussian distribution of the optical intensity mode. This decreases the beam energy utilization efficiency and increases the laser damage probability for the optics in high-power laser systems. Therefore, this study presents the design and fabrication of a novel integrated dual-aspheric beam shaper for transforming the Gaussian beam of high-power fiber lasers into a collimated flat-top profile while preserving the phase distribution with a high fill factor. Addressing the manufacturing challenges of the small-aperture, steeply curved of the shaper and the hard-to-machine characteristics of fused silica, this research employs elliptical ultrasonic vibration cutting (EUVC) technology as a low-damage processing method for fused silica beam shapers manufacturing. Kinematic analysis confirms that the periodic tool-workpiece separation in EUVC reduces cutting forces. Subsurface damage (SSD) detection experiments demonstrate a 60 % reduction in SSD compared to conventional ultraprecision cutting. Analysis indicates that discontinuous tool-workpiece contact suppresses micro-crack propagation. Laser shaping experiments validate that the EUVC fabricated shaper achieved controlling the intensity distribution of the fiber laser into flat profiles and realized a far-field energy concentration of 50.19 %, a near-field uniformity of 83.44 % and a laser-induced damage threshold (LIDT) of 10 kW/cm<sup>2</sup>, confirming its significant potential for high-power fiber laser shaping.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 235-245"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145978612","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 : 2026-05-01Epub Date: 2026-01-06DOI: 10.1016/j.precisioneng.2026.01.009
Wei Sun , Shenglong Zhang , Xiaozhe Yang , Xu Yang
Medium-carbon steel valve cores are critical precision components in digital hydraulic systems, requiring exceptional surface quality and dimensional accuracy. Electrochemical polishing (ECP) is an efficient, non-destructive surface finishing technique that has been extensively employed for a variety of metallic components. However, existing polishing methods for valve cores with complex features, including stepped geometries, continue to encounter challenges in achieving both conformality and high surface quality. In this study, a novel Pulse Electrochemical Conformal Polishing (PECP) technique is proposed and systematically evaluated for its applicability to medium-carbon steel valve cores. The conformal polishing mechanism is elucidated by analyzing the interplay of periodic salt film formation and electric field distribution during the PECP process. Subsequently, experiments were conducted with various pulse widths (0.1 s, 0.5 s, 1 s, 2 s, and 3 s) to investigate their influence on surface roughness, profile conformity, and bubble behavior. The results indicate that a pulse width of 2 s achieves optimal surface quality, reducing surface roughness (Sa) from 1.365 μm to 0.920 μm. Building upon these findings, the introduction of rotational motion further enhanced polishing performance, lowering the surface roughness Sa to 0.599 μm. Finally, in-situ high-speed imaging visualized the mechanisms of bubble formation and evolution during the polishing process, confirming the validity of the proposed polishing mechanism. This study provides a novel approach by successfully integrating pulse electrochemical polishing to not only improve surface quality but also, in combination with the salt film theory, achieve conformal polishing of complex workpieces. This method overcomes the challenge that traditional ECP techniques face in maintaining geometry, offering an effective solution for high-precision conformal polishing of complex stepped components.
{"title":"Conformal pulse electrochemical polishing of complex valve core components","authors":"Wei Sun , Shenglong Zhang , Xiaozhe Yang , Xu Yang","doi":"10.1016/j.precisioneng.2026.01.009","DOIUrl":"10.1016/j.precisioneng.2026.01.009","url":null,"abstract":"<div><div>Medium-carbon steel valve cores are critical precision components in digital hydraulic systems, requiring exceptional surface quality and dimensional accuracy. Electrochemical polishing (ECP) is an efficient, non-destructive surface finishing technique that has been extensively employed for a variety of metallic components. However, existing polishing methods for valve cores with complex features, including stepped geometries, continue to encounter challenges in achieving both conformality and high surface quality. In this study, a novel Pulse Electrochemical Conformal Polishing (PECP) technique is proposed and systematically evaluated for its applicability to medium-carbon steel valve cores. The conformal polishing mechanism is elucidated by analyzing the interplay of periodic salt film formation and electric field distribution during the PECP process. Subsequently, experiments were conducted with various pulse widths (0.1 s, 0.5 s, 1 s, 2 s, and 3 s) to investigate their influence on surface roughness, profile conformity, and bubble behavior. The results indicate that a pulse width of 2 s achieves optimal surface quality, reducing surface roughness (Sa) from 1.365 μm to 0.920 μm. Building upon these findings, the introduction of rotational motion further enhanced polishing performance, lowering the surface roughness Sa to 0.599 μm. Finally, in-situ high-speed imaging visualized the mechanisms of bubble formation and evolution during the polishing process, confirming the validity of the proposed polishing mechanism. This study provides a novel approach by successfully integrating pulse electrochemical polishing to not only improve surface quality but also, in combination with the salt film theory, achieve conformal polishing of complex workpieces. This method overcomes the challenge that traditional ECP techniques face in maintaining geometry, offering an effective solution for high-precision conformal polishing of complex stepped components.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 89-105"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928257","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 : 2026-05-01Epub Date: 2026-01-01DOI: 10.1016/j.precisioneng.2026.01.001
Matheus C. Almeida , Michele S. Carmelossi , Lucas G. Oliveira , José Henrique F. Gomes , Rogério S. Peruchi
In industrial processes, reliable measurement systems are fundamental for effective quality control and decision-making. This study addresses the challenge of integrating decision-maker customer preferences into multivariate measurement system analysis, focusing on repeatability and reproducibility indices (%R&R), especially in contexts where correlated quality characteristics are involved. Traditional approaches in Measurement System Analysis often neglect the varying importance of quality characteristics or their interdependencies, which can hinder accurate decision-making. To overcome these limitations, the article proposes a novel methodology based on Weighted Principal Components and prioritization of quality characteristics according to their significance. Through numerical simulations and real data from an industrial stainless steel cladding process, the proposed method is validated across 18 scenarios, highlighting how assigning varying weights to characteristics impacts multivariate R&R indices. The findings reveal that prioritization alters the system's classification, aligning it with the most significant variables while also capturing correlations among characteristics. When 90 % of the weight was assigned to a single characteristic, the multivariate R&R index closely followed its univariate counterpart, whereas with 47.5 % distributed between two characteristics, the multivariate index assumed intermediate values. Furthermore, by adjusting priorities in a real industrial measurement system, the proposed method significantly enhanced measurement accuracy, reducing the multivariate %R&R index from 8.98 % (marginal classification) to 0.76 % (acceptable classification)—a 91.5 % reduction in measurement system variability.
{"title":"Assessing drivers of measurement errors in industrial processes: A multivariate decision-making method based on customer preferences","authors":"Matheus C. Almeida , Michele S. Carmelossi , Lucas G. Oliveira , José Henrique F. Gomes , Rogério S. Peruchi","doi":"10.1016/j.precisioneng.2026.01.001","DOIUrl":"10.1016/j.precisioneng.2026.01.001","url":null,"abstract":"<div><div>In industrial processes, reliable measurement systems are fundamental for effective quality control and decision-making. This study addresses the challenge of integrating decision-maker customer preferences into multivariate measurement system analysis, focusing on repeatability and reproducibility indices (%R&R), especially in contexts where correlated quality characteristics are involved. Traditional approaches in Measurement System Analysis often neglect the varying importance of quality characteristics or their interdependencies, which can hinder accurate decision-making. To overcome these limitations, the article proposes a novel methodology based on Weighted Principal Components and prioritization of quality characteristics according to their significance. Through numerical simulations and real data from an industrial stainless steel cladding process, the proposed method is validated across 18 scenarios, highlighting how assigning varying weights to characteristics impacts multivariate R&R indices. The findings reveal that prioritization alters the system's classification, aligning it with the most significant variables while also capturing correlations among characteristics. When 90 % of the weight was assigned to a single characteristic, the multivariate R&R index closely followed its univariate counterpart, whereas with 47.5 % distributed between two characteristics, the multivariate index assumed intermediate values. Furthermore, by adjusting priorities in a real industrial measurement system, the proposed method significantly enhanced measurement accuracy, reducing the multivariate %R&R index from 8.98 % (marginal classification) to 0.76 % (acceptable classification)—a 91.5 % reduction in measurement system variability.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"99 ","pages":"Pages 106-121"},"PeriodicalIF":3.7,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928259","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}
扫码关注我们
求助内容：
应助结果提醒方式：
京公网安备 11010802042870号