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Advanced Processes and Technologies in Precision and Ultra-Precision Machining

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A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: closed (30 November 2022) | Viewed by 21847

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Special Issue Editors

Prof. Dr. Zhenzhong Wang

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Guest Editor

School of Aeronautics and Astronautics, Xiamen University, Xiamen 361005, China
Interests: precision engineering; ultra-precision machining technology
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Ri Pan

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Guest Editor

Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100022, China
Interests: ultra-precision machining technology

Dr. Xu Yang

E-Mail Website
Guest Editor

Department of Precision Engineering, Osaka University, Osaka 5650871, Japan
Interests: ultra-precision machining; surface modification; electrochemical machining

Special Issue Information

Dear Colleagues,

Ultra-precision machining is one of the important symbols of the level of advanced manufacturing technology. It has been recognized as a technology that requires sustainable development and determines the competitiveness in the future. Ultra-precision machining depends not only on ultra-precision machine tools, machining tools and process methods, but also on the corresponding ultra-precision measurement, machining environment and machine tool state control technology. In order to meet the increasing processing demand, ultra-precision machining is continuing to explore new principles, methods and applications to materials. This leads to the development of higher precision and efficiency, integrating machining, testing, and multi-functional modularization. Ultra-precision machining equipment and technology are the comprehensive applications of new technological achievements in many disciplines, but they also promote the development of many novel high-level technologies. This Special Issue aims to provide a collection of the latest research and findings in recent advances in ultra-precision machining technology and its applications.

Prof. Dr. Zhenzhong Wang
Prof. Dr. Ri Pan
Dr. Xu Yang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

ultra-precision machining technology and equipment
precision testing, measuring technology and equipment
non-traditional machining technology, process and approaches
novel concept, design, technology and applications
digitization and intellectualization of machining process
ultra precision motion control technology
aerostatic and hydrostatic technology

Published Papers (10 papers)

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Research

13 pages, 2331 KiB

Open AccessArticle

Determination of Undercutting Avoidance for Designing the Production Technology of Worm Gear Drives with a Curved Profile

by Zsuzsa Balajti

Machines 2023, 11(1), 56; https://0-doi-org.brum.beds.ac.uk/10.3390/machines11010056 - 03 Jan 2023

Cited by 3 | Viewed by 1657

Abstract

One of the most difficult production geometry tasks arising in the machining process of the elements of a drive pair is to avoid undercuts. It is a serious technological challenge to determine the production of the elements of worm gear drives avoiding the phenomenon undercut, especially in the case of a pair consisting of a curved profile worm and its mating wheel. The technology of forming the tooth surface requires a separate examination in each case, running the simulation procedure of the tool geometry and the movement conditions when forming different teeth. This article proposes a new concept for determining and then avoiding the positions of undercutting by examining the patented worm with a circular arc profile in axial section, due to its extremely advantageous aspect in terms of production technology. The cutting edge of the hob, formed from the substitutional worm, moves on the tooth surface of the worm, and produces the tooth surface of the conjugate wheel. The gear tooth surface has been determined based on the main law of gearing with the lines consisting of the contact points of the conjugated surfaces. The conditions for the disappearance of the common normal or the relative velocity fitting to the common tangent plane of the contacting points are defined in this paper. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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13 pages, 4148 KiB

Open AccessArticle

Preparation Technology of Stretchable Electrode Based on Laser Cutting

by Liang Dong, Kangqi Fan, Yuhang Feng, Mengxi Zhao, Xingmeng Qin, Zhaofei Zhu and Chen Li

Machines 2022, 10(10), 854; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10100854 - 25 Sep 2022

Cited by 1 | Viewed by 1882

Abstract

Wearable electronics have showed their profound impact in military, sports, medical and other fields, but their large-scale applications are still limited due to high manufacturing costs. As an advanced micro-fabrication process, laser processing technology has the advantages of high speed, high flexibility, strong controllability, environmental protection and non-contact in preparing micro-nano structures of wearable electronics. In this paper, a 355 nm ultraviolet laser was used to pattern the copper foil pasted on the flexible substrate, and the interconnection electrodes and wires were constructed. A processing method of multi-parallel line laser cutting and high-speed laser scanning is proposed to separate and assist in peeling off excess copper foil. The process parameters are optimized. A stretchable 3 × 3 light-emitting diode (LED) array was prepared and its performance was tested. The results showed that the LED array can work normally under the conditions of folding, bending and stretching, and the stretch rate can reach more than 50%. A stretchable temperature measurement circuit that can be attached to a curved surface was further fabricated, which proves the feasibility of this process in the fabrication of small-scale flexible wearable electronic devices. Requiring no wet etching or masking process, the proposed process is an efficient, simple and low-cost method for the fabrication of stretchable circuits. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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15 pages, 3838 KiB

Open AccessArticle

Precision Design of Transmission Mechanism of Toggle Press Based on Error Modeling

by Xinyu Dong and Yu Sun

Machines 2022, 10(8), 717; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10080717 - 21 Aug 2022

Viewed by 2649

Abstract

The position accuracy of the bottom dead centre (BDC) of a slider is a crucial performance index to measure the quality of a multi-link mechanical press. At present, the research on improving the position accuracy of the BDC mainly focuses on error compensation, and there is a lack of research on the tolerance design of the transmission mechanism according to the accuracy requirements of the BDC. In this paper, the motion output accuracy of the press is characterized by the position error of the BDC of the slider and the inclined angle error of the slider. Based on the loop increment method, the error transmission model of the transmission mechanism of a multi-link mechanical press was established. The key error factors that affect the output accuracy of the press were determined by analysis of error sensitivity. On this basis, a precision synthesis method considering manufacturing cost and BDC precision reliability was proposed. Finally, a Monte Carlo simulation and experiments on a toggle mechanical press were conducted to verify the model. The results show that the proposed error model and optimization method are feasible and effective. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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19 pages, 10177 KiB

Open AccessArticle

A Magnetic Abrasive Finishing Process with an Auxiliary Magnetic Machining Tool for the Internal Surface Finishing of a Thick-Walled Tube

by Yanzhen Yang, Yuan Xue, Binxun Li, Yongjian Fu, Yinghan Jiang, Rongxin Chen, Wei Hang and Xu Sun

Machines 2022, 10(7), 529; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10070529 - 29 Jun 2022

Cited by 5 | Viewed by 1661

Abstract

This paper proposes a novel magnetic abrasive finishing (MAF) process that uses an auxiliary magnetic machining tool for the internal surface finishing of a thick-walled tube. The auxiliary magnetic machining tool and external poles form a closed magnetic field circuit. Thus, a stronger magnetic force can be generated during the process. In the current study, we focus on analyzing the distribution of the magnetic field and magnetic flux density and investigating the finishing characteristics of a mixed magnetic abrasive finishing process and speed of relative revolutions. Based on the finishing characteristics, we also conduct a stage-by-stage finishing process by changing the combinations of the mixed magnetic abrasive finishing process. The finishing quality of the internal surface was mainly evaluated by the measured roundness and surface roughness. The experimental results show that the roundness and surface roughness Ra are affected when the total amount of WA abrasive and iron powder is too much; a better surface roughness could be obtained when the difference in the speed of relative revolutions is considerable, but the roundness is the worst. Furthermore, the original roundness measurement of 270 µm can reach 10 µm, and the surface roughness Ra can increase from an original surface roughness of 4.1 µm to reach 10 nm after 105 min of the stage-by-stage finishing process. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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24 pages, 4101 KiB

Open AccessArticle

Dynamic Evaluation Method of Straightness Considering Time-Dependent Springback in Bending-Straightening Based on GA-BP Neural Network

by Qingshun Kong and Zhonghua Yu

Machines 2022, 10(5), 345; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10050345 - 07 May 2022

Cited by 1 | Viewed by 1710

Abstract

There is a time-dependent springback phenomenon seen during the process of the bending-straightening of slender shafts, which has a great influence on the evaluation of straightness after straightening, creating a risk of misjudgment. This paper presents a dynamic evaluation method of straightness considering time-dependent springback in the bending-straightening process. Firstly, based on viscoelastic mechanics and bending-straightening, the influencing factors of time-dependent springback were analyzed on the basis of certain assumptions, including straightening stroke.

δ_{C}

, fulcrum distance L, instantaneous springback

δ_{b}

, straightening time

t_{s}

, and straightening force

F_{m a x}

. As the main part of the proposed dynamic evaluation method, the GA-BP neural network is used to establish a model for fast prediction of time-dependent springback in straightening, and it is compared with the linear regression model. The maximum prediction error of the GA-BP model was 0.0038 mm, which was much lower than that of the regression model, at 0.014 mm. The root mean square error (RMSE) of the GA-BP model was 0.0042, and that of the regression model was 0.0098. Finally, the effectiveness of the dynamic straightness evaluation method considering time-dependent springback is verified by experiments. Finally, the sensitivity and relative importance of the influencing factors are analyzed, and the order is

δ_{C} > t_{s} > F_{m a x} > L > δ_{b}

. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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17 pages, 5081 KiB

Open AccessArticle

Study on the Static Characteristics of a Pre-Pressure Single-Action Membrane-Type Restrictor Used in a Single Oil Pad

by Feng Lu, Zhenzhong Wang, Pengli Lei and Yi Chen

Machines 2022, 10(5), 302; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10050302 - 24 Apr 2022

Cited by 1 | Viewed by 1667

Abstract

In order to further improve the static stiffness of the hydrostatic bearing with the membrane-type restrictor, in this study, a static characteristics model of the pre-pressure single-action membrane-type restrictor (PSMR) is derived, and the criteria for achieving the optimum stiffness of the restrictor are summarized. A PSMR design method following the criteria of optimal stiffness is proposed. Then, the effect of design parameters on the performance of the restrictor is accurately evaluated by numerical simulation and orthogonal experiment with the grinder oil pad, as an example. Finally, the performance of the PSMR is compared with that of the traditional restrictors, and the main source of design error of the membrane-type restrictor is discussed. The results show that the effect of the design error of the membrane structure on the performance of the restrictor is reduced to some extent by the parallel oil circuit of the PSMR. In addition, the membrane-type restrictor designed according to the method of this paper theoretically has better static stiffness than the single-action membrane-type restrictor without pre-pressure, with an average improvement of about 14.14%. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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14 pages, 4413 KiB

Open AccessArticle

Process Optimization of Robotic Polishing for Mold Steel Based on Response Surface Method

by Yinhui Xie, Guangsheng Chang, Jinxing Yang, Mingyang Zhao and Jun Li

Machines 2022, 10(4), 283; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10040283 - 18 Apr 2022

Cited by 6 | Viewed by 2345

Abstract

Aimed to reduce surface roughness (Ra) and improve surface quality of mold steel, the optimizations of process parameters for robotic polishing, such as polishing pressure, feed speed and rotating speed of tool, are accomplish in this research. The optimum range of each parameter is obtained according to a single factor experiment, and the central composite design experiments on the three polishing parameters are conducted to establish a prediction model of surface roughness. Furthermore, a significance test of the prediction model is carried out through variance analysis. The optimum polishing parameters are obtained based on the analysis of response surface, and are then adopted in the polishing experiments of mold steel for validation. The experiment result of model verification indicates that the relative errors of predicted Ra ratio and actual Ra ratio are within the allowable range (maximum is 13.47%). It proves the accuracy of the roughness prediction model. Meanwhile, the experimental results of multipath polishing show that the surface roughness decreased effectively after polishing with the optimum polishing parameters. The prediction model of surface roughness and optimum polishing parameters are helpful to improve surface quality in robotic polishing for mold steel. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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18 pages, 9618 KiB

Open AccessArticle

Research on Machining Error Analysis and Traceability Method of Globoidal Indexing Cam Profile

by Shuwen Sun, Yunfei Qiao, Zhentao Gao and Chao Huang

Machines 2022, 10(3), 219; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10030219 - 21 Mar 2022

Cited by 1 | Viewed by 2005

Abstract

The profile of the globoidal indexing cam is a spatially undevelopable surface. It needs a special computer numerical control (CNC) machine tool to finish batch production, and its machining quality will be affected by the motion error of each part of the machine tool and the clamped positioning error of the workpiece. Firstly, the mathematical model of the error of the machine tool for machining the globoidal cam surface is derived, and the influence of the error of the machine tool for machining the globoidal cam surface is given. Secondly, an error tracking method for globoidal cam profile machining error based on error sensitivity coefficient grouping is proposed, which improves the data processing speed and the accuracy of the tracking results. Finally, the error analysis and traceability method of the globoidal cam is verified by experiments, and the error traceability results are fed back to the processing link. The machining quality of globoidal cam is improved by the error compensation, which provides the key technology for the integration of the design, manufacture, and measurement of the globoidal cam. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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15 pages, 5943 KiB

Open AccessArticle

Clarification of the Mechanism of Pulse Laser Grinding of Nanosecond Lasers Using High-Speed Camera Imaging

by Xiaoxu Liu, Xianlong Ni, Osamu Konda, Hiroko Furuhashi, Satoru Maegawa and Fumihiro Itoigawa

Machines 2022, 10(3), 196; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10030196 - 08 Mar 2022

Cited by 4 | Viewed by 2527

Abstract

Pulse laser grinding (PLG), as a cutting tool processing method, can not only achieve edge sharpening with high precision, but it can also produce surface modification. For example, polycrystalline cubic boron nitride (PCBN) tools processed by PLG can show increased hardness due to the reduction in defects. However, the mechanism of edge formation under PLG processing remains unclear. In this study, by observing the plasma generated during processing using a high-speed camera, the elementary process for each laser pulse of the PLG process was visualized. The plasma luminescence moved successively through four stages: multipoint luminescence, uniform luminescence, the downward movement of the luminous center, and faint luminescence. By comparing the results of three different laser pulse pitches (0.2, 2, and 20 μm), it was found that the pulse pitch had a significant influence on the PLG processing mode. When the pulse pitch was too small, the sidewall effect was likely to lead to local excess machining. The large pulse pitch resulted in processed surfaces that could not be fully covered by laser irradiation, and it was preferred to remove the decrease threshold subsequently. Thus, the moderate pulse pitch condition showed a superior processed surface compared to the others. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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16 pages, 4399 KiB

Open AccessArticle

Fixed Abrasive Polishing in an Anhydrous Environment: A Material Removal Model for Fused Silica

by Yuan Qian, Wei Yang, Chaoxu Chen and Xiaoluo Yu

Machines 2022, 10(2), 147; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10020147 - 17 Feb 2022

Cited by 5 | Viewed by 2081

Abstract

Due to the prevalent randomness and uncertainties associated with traditional loose polishing, fixed abrasive polishing in an anhydrous environment has been chosen as a new polishing method. In this paper, cerium oxide is the main component for polishing pellets, and the particle size distribution of cerium oxide is measured. A material removal model for fixed abrasive polishing of fused silica in an anhydrous environment is proposed. Based on this model, we simulate the roughness of fused silica in fixed abrasive polishing process by using a Monte Carlo method with a constant removal mechanism and obtain the percentage of plastic and chemical removal. The percentage result is then taken into the material removal equation to calculate the material removal rate. The final convergence value of the roughness with 2 μm particle size is about 1.8 nm, while the final convergence value of the surface roughness of the workpiece by Monte Carlo simulation is about 1 nm. The experimental material removal rate at 2 μm particle size is 5.48 μm/h, while the simulation result is 4.29 μm/h. The experiment data of roughness and material removal rate all verify the model. Full article

(This article belongs to the Special Issue Advanced Processes and Technologies in Precision and Ultra-Precision Machining)

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