Article
Engineering, Industrial
Shengjun Ao, Hu Gong, Kuntao Huang
Summary: This study presents a smooth tool path interpolation algorithm for ultraprecision turning discontinuous multi-freeform surfaces, reducing following errors and improving machining efficiency.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Kodai Nagayama, Jiwang Yan
Summary: In this study, a deterministic process flow was proposed to achieve nanometer-level form accuracy in STS turning by analyzing, simulating, and compensating for main error factors. The proposed method successfully reduced form error to 8 nm P?V and achieved a surface roughness of 1 nm Sa through a single cut.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Automation & Control Systems
Marco Buhmann, Erich Carelli, Christian Egger, Klaus Frick
Summary: This study proposes a new computation method for tool path generation in three-axis corrective machining, using numerical approximation techniques to calculate surface normal vectors and maintain consistent radial axis motion, achieving error values below 1 nm.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Multidisciplinary
Yanjun Guo, Xiaojing Yang, Jie Kang, Tong Yao, Bohan Cheng, Maozhong Li, Qiming Xie
Summary: This study proposes a multi-objective optimization method for tool path generation based on a novel surface analysis model for ultra-precision diamond turning of freeform surfaces. It establishes a relation between cutting point sampling details and the resulting form error of freeform surfaces. The non-dominated sorting genetic algorithm (NSGA-II) is used to solve the optimization problem and obtain the pareto optimal solution of the cutting point sampling parameters.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Shigeru Tanikawa, Yusuke Sato, Jiwang Yan
Summary: With the advancement of optical technologies such as VR and 3D sensing, there is a growing demand for optical components with complex shapes. Ultra-precision diamond turning is a common method used for freeform optics. However, a time delay caused by the independent control system of the fast tool servo (FTS) can lead to angular misalignment and form errors. In this paper, a novel method for measuring and compensating for the time delay was proposed, resulting in improved form accuracy for freeform optics.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Yanjun Guo, Xiaojing Yang, Jie Kang, Wanqing Zhang, Xueying Wang, Maozhong Li, Yuankang Wang, Qiming Xie, Shengyang Luo
Summary: This study investigates the machining mechanisms and parameters of single-crystal germanium using ultra-precision diamond turning. A ductile machining model considering feed rate, cutting depth, and surface slope is proposed. Additionally, a novel taper cutting test is used to determine the critical ductile-brittle transition depth. The results demonstrate that a smaller feed rate and cutting depth can achieve ductile machining for freeform surfaces with large surface slopes. The study successfully fabricates a freeform surface of single-crystal germanium with low form error and surface roughness.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Automation & Control Systems
Shengyuan Yang, Deping Yu, Hong Yang, Yanbing Feng, Xiaoming Liu, Zhengxin Yin
Summary: This paper presents a hybrid tool servo (HTS) diamond turning technique to efficiently produce multiscale optical surfaces (MOS) with special optical advantages. By integrating the characteristics of different servo systems and conducting tool path evaluations, the new technique successfully meets the strict manufacturing requirements of MOS. A machining experiment of a typical MOS demonstrates the effectiveness of the proposed technique in fabricating optical surfaces with minimal profile errors.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Multidisciplinary
Neil J. Naples, Allen Y. Yi
Summary: This paper presents a 3D blending surface that is used to smoothly join two non-intersecting surfaces in freeform optics manufacturing. The proposed blending surface enables the smooth transition between different domains and handles the discontinuity at surface intersections. Experimental results show that increasing the order of the blending polynomial improves the overall continuity of the blended surface. The paper also demonstrates the robustness of the surface blending technique in generating toolpaths for a freeform microlens array.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Neil J. Naples, Allen Y. Yi
Summary: The complexity of freeform optics drives the complexity of manufacturing processes. This paper develops toolpath generation techniques for specified surfaces and explores the transition between surfaces. The proposed extrapolating surface can modify a freeform surface outside its defined boundary to increase overall continuity of the toolpath.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Lin Zhang, Yusuke Sato, Jiwang Yan
Summary: This manuscript proposes a novel adaptive control points sampling strategy to improve form accuracy and retain as many micro surface features as possible. By adjusting the sampling stepovers between control points to adapt to surface profile variation, the proposed method constrains interpolation error within tolerance and eliminates issues of insufficient/excessive control points in the machining area. Compared to the constant sampling method, the form error of the proposed method is reduced by about 35% in both theoretical predictions and experimental measurements with the same number of control points. This technique provides a new route for allocating control points in FTS diamond turning to achieve high form accuracy and machining efficiency in the fabrication of freeform optics.
JOURNAL OF ADVANCED MECHANICAL DESIGN SYSTEMS AND MANUFACTURING
(2023)
Article
Automation & Control Systems
Yuan-Liu Chen, Zhongwei Li, Fuwen Chen, Huanbin Lin, Bing-Feng Ju, Yi Liu
Summary: The three-axis fast tool servo system achieves high precision, low parasitic motion, and high practicality through optimized design, effectively realizing the processing of complex microstructures.
IEEE-ASME TRANSACTIONS ON MECHATRONICS
(2022)
Article
Automation & Control Systems
Yuan-Liu Chen, Zhongwei Li, Fuwen Chen, Huanbin Lin, Bing-Feng Ju, Yi Liu
Summary: A three-axis fast tool servo (FTS) with a symmetric structure design has been developed for ultraprecision diamond cutting to achieve high tracking accuracy while maintaining high stiffness and open-loop bandwidth performance. Modeling, analysis, and optimization using the finite-element method in six degree-of-freedom were conducted to design the mechanism. Experiments confirmed low parasitic motion, high tracking accuracy, and high dynamic response in the three-axis FTS system.
IEEE-ASME TRANSACTIONS ON MECHATRONICS
(2022)
Article
Materials Science, Multidisciplinary
Zejia Zhao, Yexiang Fu, Suet To, Guoqing Zhang, Jianjun Lin
Summary: This paper investigates the effect of material microstructural on the wear of single crystal diamond tools during ultraprecision turning of difficult-to-cut Ti6Al4V alloys. The results show that the flank face of Ti6Al4V workpiece has more adhesion than the rake face, and the tool wear is less in turning of the lamellar alloy compared to the equiaxial and bimodal alloys, resulting in low cutting forces and high surface quality. The wear mechanism of the diamond tool is discussed from the perspectives of wear modes and chemical reactions.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2023)
Article
Optics
Changfu Lang, Chuang Li, Hang Fu, Sui Bo, Chao Yang, Changxi Xue
Summary: The machining of freeform surfaces is a current research hotspot. A hybrid slow-fast tool servo method combining slow tool servo (STS) and fast tool servo (FTS) was proposed to machine large steep freeform surfaces. Experimental studies showed that this method improved processing efficiency and achieved good surface roughness.
Article
Engineering, Multidisciplinary
Nicholas Yew Jin Tan, Guangya Zhou, Kui Liu, A. Senthil Kumar
Summary: The study of spectral signatures of various elements has been made possible through the ability to diffract light with optical gratings and control light with lenses and mirrors. As devices aim to become more compact while maintaining efficiency, integration of functions is necessary to reduce component count. However, the challenge lies in manufacturing integrated microstructures on complex forms due to lack of axial flexibility.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Article
Automation & Control Systems
Jing Hong, Lin Zhang, Zhiyu Zhang, Hu Huang, Jiwang Yan
Summary: A comparative study was conducted on mechanical polishing (MP) and laser polishing (LP) as methods for improving the quality of laser-nitrided surfaces. The results showed that LP significantly reduced surface roughness and achieved remarkable improvements in surface quality.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Lin Zhang, Yusuke Sato, Jiwang Yan
Summary: This manuscript proposes a novel adaptive control points sampling strategy to improve form accuracy and retain as many micro surface features as possible. By adjusting the sampling stepovers between control points to adapt to surface profile variation, the proposed method constrains interpolation error within tolerance and eliminates issues of insufficient/excessive control points in the machining area. Compared to the constant sampling method, the form error of the proposed method is reduced by about 35% in both theoretical predictions and experimental measurements with the same number of control points. This technique provides a new route for allocating control points in FTS diamond turning to achieve high form accuracy and machining efficiency in the fabrication of freeform optics.
JOURNAL OF ADVANCED MECHANICAL DESIGN SYSTEMS AND MANUFACTURING
(2023)
Article
Engineering, Industrial
Weihai Huang, Jiwang Yan
Summary: Ultrasonic vibration cutting (UVC) is a promising technology for processing hard-brittle materials in a ductile mode. This study used cyclic nanoindentation to reveal the mechanism of UVC in monocrystalline silicon (Si) and found that cyclic loading promotes silicon amorphization and decreases the threshold for phase transition. Furthermore, the critical cutting depth for brittle-to-ductile transition and the degree of amorphization in cutting chips increase in UVC compared to conventional cutting.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Chemistry, Multidisciplinary
Mingming Cui, Hu Huang, Lin Zhang, Jiwang Yan
Summary: In this study, a new nanosecond laser pulling method is proposed to fabricate micro-nano structures on metallic glasses. The formation mechanism and evolution of the micro-nano bulge are investigated, and various micro-nano structures are successfully created on the MG surface, affecting the surface optical diffraction. Overall, this study provides a highly flexible and controllable method for the fabrication of micro-nano structures on MGs.
Review
Engineering, Manufacturing
Weihai Huang, Jiwang Yan
Summary: Brittle materials are widely used in optics, optoelectronics, and semiconductors. Ultraprecision machining of brittle materials can improve their functional performance and lifespan. This paper provides a comprehensive overview of recent advances in ultraprecision machining of soft-brittle materials, comparing different machining methods and analyzing their effects on tool-workpiece interactions. The paper also identifies challenges in engineering applications and provides solutions and guidelines for future research and development.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2023)
Article
Materials Science, Ceramics
Zhanchen Zhu, Tianfeng Zhou, Yupeng He, Qian Yu, Xibin Wang, Tao Yan, Jiwang Yan, Haihui Ruan
Summary: In this study, a novel two-step precision glass molding (PGM) process is proposed for the fabrication of chalcogenide (ChG) glasses with micro-nano structure arrays. A nickel-phosphorus (Ni-P) mold is used to transfer the antireflective micro-nano structure array to silicate glass, which is then used as a mold to replicate the structured surface onto the ChG glass. The results demonstrate high forming accuracy and favorable infrared optical transmission characteristics of the ChG glass micro-nano structure array, while the silicate glass proves to be a suitable mold material for the ChG glass molding process. This work provides a novel PGM technique for ChG glass materials.
CERAMICS INTERNATIONAL
(2023)
Article
Chemistry, Physical
Jing Hong, Haoxiang Wu, Hu Huang, Lin Zhang, Zhiyu Zhang, Minqiang Jiang, Jiwang Yan
Summary: In this study, nanosecond laser nitriding was used to improve the surface hardness and tribological characteristics of metallic glasses. Three laser nitrided surfaces with different hardness were prepared and their tribological characteristics were systematically investigated. The results showed that the hardness of the laser nitrided surfaces increased by 47.94%, 114.56%, and 171.99% compared to the original alloy, and the coefficients of friction were reduced by 29.12%, 65.05%, and 71.84%, respectively. Additionally, the scratch damage mechanisms were analyzed based on the various features of residual scratches and surrounding chips under different conditions.
Article
Materials Science, Multidisciplinary
Yuka Yamamuro, Tomotaka Shimoyama, Jiwang Yan
Summary: Femtosecond pulsed laser irradiation was used to generate numerous nanopores on the surface of yttria-stabilized zirconia (YSZ) without causing thermal damage to the material. The nanopore generation mechanism involved light focusing and ablation inside the YSZ grains. This study demonstrates the feasibility of selectively fabricating nanopores on YSZ surfaces for various applications.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Manufacturing
Weihai Huang, Jiwang Yan
Summary: In this study, the tool-workpiece interaction mechanisms in cutting curved microstructures on 4H-SiC (0001) were explored through ultraprecision diamond turning. It was found that microcracks easily occurred in the feed-in/cut-in area of the micro-dimples due to large friction-induced tensile stress. Dimples located on different cleavage directions exhibited varying tendencies to cause surface cracking and had different subsurface damage characteristics.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2023)
Article
Materials Science, Multidisciplinary
Chao Wang, Hu Huang, Mingming Cui, Zhiyu Zhang, Lin Zhang, Jiwang Yan
Summary: Superhydrophobicity was achieved on the FeCoCrMnNi surface by synergistic laser texturing and low temperature annealing. Textured surfaces exhibited excellent superhydrophobicity at different hatching intervals and a maximum contact angle of 165 degrees was obtained. The created superhydrophobic surfaces possessed good liquid capture, self-cleaning capabilities, and enabled magnification for optical imaging.
JOURNAL OF LASER APPLICATIONS
(2023)
Article
Engineering, Industrial
Yupeng He, Tianfeng Zhou, A. Senthil Kumar, Xibin Wang, Jiwang Yan
Summary: The shear interference and chip removal interference between different tool edges during non-free cutting are the main reasons for the deformation of micron-submicron grooves. This paper presents a new variable shear angle removal model to understand the material removal mechanism and cutting-induced deformation of micron-submicron grooves in non-free cutting. Finite element simulations and high-speed cutting experiments are conducted to analyze the cutting microstate and dynamic deformation of the micron-submicron grooves.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Shigeru Tanikawa, Yusuke Sato, Jiwang Yan
Summary: With the advancement of optical technologies such as VR and 3D sensing, there is a growing demand for optical components with complex shapes. Ultra-precision diamond turning is a common method used for freeform optics. However, a time delay caused by the independent control system of the fast tool servo (FTS) can lead to angular misalignment and form errors. In this paper, a novel method for measuring and compensating for the time delay was proposed, resulting in improved form accuracy for freeform optics.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Toshiki Tsuchida, Weihai Huang, Jiwang Yan
Summary: This study investigates the processing characteristics of yttria-stabilized zirconia (YSZ) ceramic under ultrasonic vibration-assisted burnishing (UVB) enhanced by flexible stage and tool rotation techniques. The results show that the use of flexible stage-enhanced UVB reduces the fluctuation of burnishing force and produces a smooth surface with a reduced surface roughness. The use of tool rotation-enhanced UVB forms arc-shaped surface textures and further reduces the surface roughness. Stress-induced phase transformation of YSZ is observed in all burnished surfaces. This study demonstrates the feasibility of manufacturing YSZ with a smooth surface and high residual compressive stress.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2023)
Article
Engineering, Manufacturing
Mohamed Wagih, Ibrahem Maher, Hassan El-Hofy, Jiwang Yan, Mohsen A. Hassan
Summary: Trochoidal milling is a machining method used to extend cutting tool life. This paper analyzes and experiments the elliptical tool path and proposes a novel linear-elliptical tool path to enhance the performance. The effects on material removal rate, cutting forces, walls waviness, and surface roughness are investigated. The results show improved material removal rate and surface quality, making the linear-elliptical paths promising in increasing the performance of trochoidal milling.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2023)
Article
Engineering, Industrial
Weihai Huang, Kodai Nagayama, Jiwang Yan
Summary: This study investigates the fabrication of spherical and hexagonal microlens arrays on calcium fluoride (CaF2) using diamond turning. The study demonstrates that microcracks tend to be generated during the cutting process, especially when cutting along specific directions. By reducing the maximum undeformed chip thickness and using a depth-offsetting segment cutting method, high-quality microlens arrays without surface cracking can be achieved. This study proves the feasibility of fabricating high-quality freeform microstructured surfaces on CaF2 and other soft-brittle materials through diamond turning.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)