Dimensional Tolerances Research Articles

Design and Performance Characteristics of Single-Axis Tracking Dual Confocal Low-Magnification Parabolic Trough CPV system

With the rapid increase of PV module utilization, the environmental pollution associated with waste photovoltaic (PV) module and its recycling is of concern. This paper proposes a concentrating photovoltaic (CPV) system to reduce the use of PV module. The cross-confocal method is employed for the concentrator to eliminate central dark streaks. In optical simulation, a theoretical uniformity index of 0.0466 and a theoretical optical efficiency of 89.87% were achieved. When the distance between the rotational axis and the center of gravity is less than 125.8mm, the system can withstand winds of 20.4m/s. The temperature range of the PV, obtained from finite element analysis, is from 295.71 K to 363.13 K. With the requirements of the relative optical efficiency of over 90% and the uniformity index of less 0.5, the system has a dimensional translation tolerance of approximately ±10mm, a dimensional rotation tolerance of about 5°, and a tracking angle tolerance of about 1°. The actual daily average output current of this system has increased by 100.91%. The ratio between the increase ratio of output current and the theoretical concentration ratio is 83.4%. The system demonstrates excellent optical performance and system tolerance.

Achieving a near-ideal silicon crystal neutron interferometer using submicrometer fabrication techniques

Perfect-crystal neutron interferometry, which is analogous to Mach-Zehnder interferometry, uses Bragg diffraction to form interfering neutron paths. The measured phase shifts can be used to probe many types of interactions whether it be nuclear, electromagnetic, gravitational, or topological in nature. For a perfect-crystal interferometer to preserve coherence, the crystal must possess a high degree of dimensional tolerance as well as being relatively defect-free with minimal internal stresses. In the past, perfect-crystal neutron interferometers have been produced by a two-step process. First, a resin diamond wheel would be used to remove excess material and shape the interferometer. Afterword, the crystal would be etched to remove surface defects and elevate strains. This process has had limitations in terms of repeatability and in maximizing the final contrast, or fringe visibility, of the interferometer. We have tested various fabrication and post-fabrication techniques on a single perfect-crystal neutron interferometer and measured the interferometer's performance at each step. Here we report a robust, nonetching fabrication process with high final contrast. For the interferometer used in this work, we achieved contrasts of greater than 90% several times and ultimately finished with an interferometer that has 92% contrast and a uniform phase distribution. Published by the American Physical Society 2024

Kinematic Reliability of Manipulators Based on an Interval Approach

Robotic manipulators inevitably experience the impact of uncertainties and errors, such as dimensional tolerances and joint clearances. Therefore, this paper proposes a novel method based on an interval approach to evaluate the kinematic reliability of manipulators. Kinematic reliability quantifies the probability of positioning errors that fall within allowable boundaries. As a result, reliability evaluates the probability that the interval end-effector error produced by dimensional tolerances exceeds an acceptable rate. The proposed reliability index is based on the interval error that conveys an alternative approach to the kinematic reliability methods based on probabilistic frameworks reported in the literature based on probabilistic approaches. The obtained numerical results demonstrate the viability of the proposed methodology by evaluating the reliability of a serial manipulator subjected to joint clearances and a parallel manipulator with dimensional tolerances.

Effect of tool orientation on surface roughness and dimensional accuracy in ball end milling of thin-walled blades

AbstractIn the aerospace industry, high-precision components like impellers and blisks present considerable challenges in machining due to their intricate geometries and the need for reliable performance. Blades, often classified as thin-walled parts with complex, free-form surfaces, are crucial in ensuring the efficiency and safety of aircraft engines. Their geometries and materials require strict control over cutting parameters, such as tool path and orientation, to avoid deformation and maintain surface integrity. This study investigates the impact of tilt angle variation during ball end milling of Ti6Al4V thin-walled parts. Four different tilt angles (15°, 30°, 45°, and 60°) were analysed to evaluate their effect on dimensional accuracy and surface roughness. The results show that tilt angle significantly influences surface quality and dimensional precision. A tilt angle of 30° achieved the best balance between surface finish and dimensional tolerances, with flatness values ranging from 0.038 mm at 30° to 0.101 mm at 60°, representing a 152.5% increase in flatness. The findings provide practical guidelines for optimizing ball end milling of thin-walled components, emphasizing the importance of tool orientation in reducing deformation and enhancing surface quality.

Enhancing the machinability and formability of tool steels through spheroidizing annealing heat treatment

This research focuses on enhancing the machinability and formability of tool steels by applying different heat treatment scenarios. Machinability is the process of cutting metals with the least energy effort, while formability is the ability of a metal to be shaped into different forms without severe damage. Enhancing machinability and formability improves dimensional tolerance and surface finish and increases the lifetime and reliability of tool steels. This research will use two tool steel materials, “D2” and “O1,” which are widely used in industry. They contain high percentages of carbon by weight (1.55% and 0.95%, respectively). The “O1” tool steel is used in blanking dies and room-temperature cutting tools, whereas the “D2” tool steel is used for carpentry cutting tools and gauges. The different heat treatment scenarios are based on the latest literature, which shows excellent results with other materials. The heat treatment plan is set to cover various scenarios to determine the most effective treatment for machinability and formability. The experimental work will include several mechanical tests: tensile tests, compression tests, hardness tests, and toughness tests. The conclusions regarding the different heat treatments will be based on the test results.

Comparative evaluation of vat photopolymerization and steel tool molds on the performance of injection molded and overmolded tensile specimens

AbstractThis study explores the use of vat polymerization stereolithography (SLA) for fabricating mold tooling, subsequently utilized in injection molding (IM) and overmolding of tensile specimens and directly compared to those produced using metal molds. The results first find the manufacturing time for an SLA‐fabricated mold is remarkably short, approximately 6 h, presenting a substantial improvement over traditional methods. Mechanical testing revealed that the tensile specimens from the SLA‐fabricated molds exhibited the highest tensile strength among all overmolding batches. This performance was consistent with the tensile bars produced using metal molds, demonstrating the viability of SLA‐fabricated molds for overmolding applications and highlighting the potential of FDM to customize the properties of final products. However, variations in mold types impacted the dimensional tolerance and tensile strength of the final specimens. Metal mold‐fabricated tensile bars exhibited superior dimensional accuracy and maximum tensile strength (50.6–61.7 MPa) compared to those produced with SLA‐fabricated molds (46.9–55.9 MPa). These differences are attributed to the rougher surface finish inherent to the layer‐by‐layer construction of SLA and the internal stresses and defects resulting from lower thermal conductivity and uneven cooling. In conclusion, this study underscores the promising future applications of SLA‐fabricated molds in overmolding, offering reduced manufacturing costs and enhanced design freedom. The findings support the potential of SLA to revolutionize mold fabrication, thereby extending its utility and optimizing the production of polymer components with customized properties.Highlights SLA molds compared to metal molds for direct injection molding and overmolding. FFF preforms with varied geometries were overmolded to finalize the specimens. Joint configurations in overmolding improved tensile performance. Overmolding showed better dimensional accuracy than FFF specimens. SLA mold preparation significantly reduced manufacturing costs.

Effect of heat treatment on the anisotropic machinability of additive manufactured titanium alloys in micro-milling

For titanium alloy parts prepared by selective laser melting (SLM), post-treatment operation is usually utilized to meet the needed surface accuracy and dimensional tolerances. However, the heat treatment process and anisotropy of different surfaces of SLMed titanium alloy can directly affect its machinability. In this study, the anisotropic machinability of SLMed TC4 before and after heat treatment was comprehensively compared by the milling force, surface quality, top-burr and work hardening. The results indicate that the milling force and work hardening degree of top surface of SLMed TC4 material are larger than those of side surface, and top surface the presents the better surface quality and smaller top-burr. It exhibits obvious anisotropic machinability in micro-milling. After heat treatment, the anisotropic machinability between different surfaces of SLMed TC4 materials were significantly reduced. The average surface roughness difference rate of top and side surfaces decreased from 10.08% to 2.79%, and the total average top-burr size difference rate decreased from 19.53% to 9.99%. The difference rate of milling force and work hardening degree of the top and side surfaces both showed a decreasing trend. This work demonstrates that the anisotropic machinability of SLMed TC4 material in micro-milling can be effectively mitigated by the heat treatment process.

Enhancing Fatigue Resistance of Polylactic Acid through Natural Reinforcement in Material Extrusion.

This research paper aims to enhance the fatigue resistance of polylactic acid (PLA) in Material Extrusion (ME) by incorporating natural reinforcement, focusing on rotational bending fatigue. The study investigates the fatigue behavior of PLA in ME, using various natural fibers such as cellulose, coffee, and flax as potential reinforcements. It explores the optimization of printing parameters to address challenges like warping and shrinkage, which can affect dimensional accuracy and fatigue performance, particularly under the rotational bending conditions analyzed. Cellulose emerges as the most promising natural fiber reinforcement for PLA in ME, exhibiting superior resistance to warping and shrinkage. It also demonstrates minimal geometrical deviations, enabling the production of components with tighter dimensional tolerances. Additionally, the study highlights the significant influence of natural fiber reinforcement on the dimensional deviations and rotational fatigue behavior of printed components. The fatigue resistance of PLA was significantly improved with natural fiber reinforcements. Specifically, PLA reinforced with cellulose showed an increase in fatigue life, achieving up to 13.7 MPa stress at 70,000 cycles compared to unreinforced PLA. PLA with coffee and flax fibers also demonstrated enhanced performance, with stress values reaching 13.6 MPa and 13.5 MPa, respectively, at similar cycle counts. These results suggest that natural fiber reinforcements can effectively improve the fatigue resistance and dimensional stability of PLA components produced by ME. This paper contributes to the advancement of additive manufacturing by introducing natural fiber reinforcement as a sustainable solution to enhance PLA performance under rotational bending fatigue conditions. It offers insights into the comparative effectiveness of natural fibers and synthetic counterparts, particularly emphasizing the superior performance of cellulose.

ROM-based stochastic optimization for a continuous manufacturing process

This paper proposes a model-based optimization method for the production of automotive seals in an extrusion process. The high production throughput, coupled with quality constraints and the inherent uncertainty of the process, encourages the search for operating conditions that minimize nonconformities. The main uncertainties arise from the process variability and from the raw material itself. The proposed method, which is based on Bayesian optimization, takes these factors into account and obtains a robust set of process parameters. Due to the high computational cost and complexity of performing detailed simulations, a reduced order model is used to address the optimization. The proposal has been evaluated in a virtual environment, where it has been verified that it is able to minimize the impact of process uncertainties. In particular, it would significantly improve the quality of the product without incurring additional costs, achieving a 50% tighter dimensional tolerance compared to a solution obtained by a deterministic optimization algorithm.

Revision of ex vivo endodontic biofilm model using computer aided design

ObjectiveMost endodontic diseases are bacterium-mediated inflammatory or necrotic process induced by contaminated dental pulp. Although great advances are being performed to obtain more efficient antibacterial strategies for persistent infections, most studies lack of representative models to test their antibacterial effects and their outcomes cannot be promptly translated to clinical practice. Therefore, this study aimed to refine an ex vivo endodontic biofilm model combining human tooth, computer guided design and 3D printing to obtain a more reproducible and predictable model. MethodsMonoradicular teeth were cut using three different methods: hand-held (HCC), mechanical precision (MPC) and computer aid guided cutting (CGC). Then, blocks were reassembled. The different model preparations were assessed in terms of dimensional tolerance, surface analysis, liquid tightness and Enterococcus faecalis biofilm development for 21 days, which was studied by metabolic assays and confocal microscopy. Then, the proposed model was validated using different commercial disinfecting treatments. ResultsCGC exhibited significantly lower deviation and surface without defects compared to HHC and MPC, leading to superior liquid tightness. Similarly, mature biofilms with high metabolic activity and vitality were observed in all conditions, CGC showing the lowest variation. Regarding the model validation, all antibacterial treatments resulted in the complete eradication of bacteria in the standard 2D model, whereas commercial treatments exhibited varying levels of efficacy in the proposed ex vivo model, from moderately reduction of metabolic activity to complete elimination of biofilm. ConclusionsThe novel guided approach represents a more reliable, standardized, and reproducible model for the evaluation of endodontic disinfecting therapies. Clinical SignificanceDuring antibacterial treatment development, challenging 3D models using teeth substrates to test antibacterial treatments novel guided approach represents a more reliable, standardized, and reproducible model for the evaluation of endodontic disinfecting therapies.

Dimensional tolerance optimization of SAR antennas with uncertainty quantification and reliability analysis based on structural-electromagnetic coupling model

The dimensional tolerances greatly impact the structural-electromagnetic performance of spaceborne synthetic aperture radar (SAR) antenna. However, few works have conducted the tolerance allocation of the extendible support structure to guarantee system reliability. To bridge the above gap, an integrated optimization methodology is proposed to design the dimensional tolerances with the structural-electromagnetic coupling model in this study. First, the absolute nodal coordinate formulation is developed to predict the structural deformation triggered by the dimensional deviations. Then, the coupling relationship between the displacement field and the electromagnetic field is elucidated for the SAR system. Subsequently, taking advantage of the surrogate model and the parallel update criterion, the interval uncertainty quantification stemming from dimensional tolerances is executed to quickly identify the worst-case scenarios of structural response. Moreover, a multi-point selection strategy is incorporated into the adaptive Bayesian probabilistic integration with active learning, which significantly improves the computational efficiency of electromagnetic reliability. Based on the above tolerance analysis, the inverse optimization design of the dimensional tolerance is realized by the particle swarm algorithm. Finally, the effectiveness and superiority of the proposed methods are validated in the case study. Our innovative framework and analytical methodology not only furnish a comprehensive structural-electromagnetic coupling model but also transition the design paradigm from experiential to robust tolerance allocation.

Nanotechnology-Enabled Rapid Investment Casting of Aluminum Alloy 7075

Abstract Rapid investment casting with additively produced molds can offer excellent surface finishes, tight dimensional tolerances, and complex geometries for high-performance metal parts in a rapid fashion. However, there is a long-standing challenge in the investment casting of high-strength aluminum alloy (AA) 7075 due to its hot cracking susceptibility and severe solidification shrinkage. Here, we show the unprecedented rapid investment casting of AA7075 by applying nano-treating technology, whereby a low-volume fraction of nanoparticles is dispersed into metal to modify its solidification behavior and microstructure. TiC nanoparticles were able to effectively modify both primary and secondary phases while suppressing the hot cracking susceptibility of AA7075 during solidification. Despite the low cooling rate, nano-treated AA7075 exhibits fine equiaxed grains with an average size of 47.1 μm, in contrast to the large dendritic grains measuring 714.8 μm in pure AA7075. Nano-treated AA7075 parts produced by rapid investment casting exhibited exceptional tensile strength and ductility in both as-cast and heat-treated conditions. This study highlights the potential of investment casting high-performance alloys which were traditionally considered impossible to fabricate by this method.

Optimizing Milling Parameters for Enhanced Machinability of 3D-Printed Materials: An Analysis of PLA, PETG, and Carbon-Fiber-Reinforced PETG

Fused deposition modeling (FDM) is widely applied in various fields due to its affordability and ease of use. However, it faces challenges such as achieving high surface quality, precise dimensional tolerance, and overcoming anisotropic mechanical properties. This review analyzes and compares the machinability of 3D-printed PLA, PETG, and carbon-fiber-reinforced PETG, focusing on surface roughness and burr formation. A Design of Experiments (DoE) with a full-factorial design was used, considering three factors: rotation speed, feed rate, and depth of cut. Each factor had different levels: rotational speed at 3000, 5500, and 8000 rpm; feed rate at 400, 600, and 800 mm/min; and depth of cut at 0.2, 0.4, 0.6, and 0.8 mm. Machinability was evaluated by roughness and burr height using a profilometer for all the materials under the same milling conditions. To evaluate the statistical significance of the influence of various processing parameters on surface roughness and burr formation in 3D-printed components made of three different materials—PLA, PETG, and carbon-fiber-reinforced PETG—an analysis of variance (ANOVA) test was conducted. This analysis investigated whether variations in rotational speed, feed rate, and depth of cut resulted in measurable and significant differences in machinability results. Results showed that milling parameters significantly affect roughness and burr formation, with optimal conditions for minimizing any misalignment highlighting the trade-offs in parameter selection. These results provide insights into the post-processing of FDM-printed materials with milling, indicating the need for a balanced approach to parameter selection based on application-specific requirements.

Panoramic Perfection: Unveiling Technical Insights from “The Henderson” in Hong Kong

The organic design and seamlessly reflective surface of “The Henderson” establish it as a landmark in Hong Kong. With its all-glass façade and a height of 210 m, the skyscraper designed by Zaha Hadid Architects offers spectacular panoramic views. Particularly noteworthy is the “Banquet Hall” on the top floor, distinguished by its fully glazed roof and engineered by Eckersley O’Callaghan. Large-format, coated and curved glass panes with the best possible technical specification in terms of thickness and minimal dimensional tolerances counterbalance architectural aesthetics and structural resilience. Engineered, manufactured and installed by seele, they serve as effective shields against solar radiation and glare, seamlessly complementing the organic architecture. Collaborative efforts focused on maximizing the transparency of the building envelope as interdisciplinary teams navigated challenges in structural engineering, design aesthetics and compliance with strict regulatory standards of the building authorities in Hong Kong. Thanks to targeted investigations, advancements in glass construction technology and engineering innovation, a procedure was developed that ensured optimum bearing of the panoramic glass panes. This project contributes to the safety and durability of high-rise glass structures to withstand extreme conditions and showcases the transformative potential of bold design concepts, rigorous testing, and international collaboration. The result is a visually stunning and structurally outstanding masterpiece.

INTERPRETATION WORKFLOW OF GEOMETRIC TOLERANCES

The application of the principles of the geometric product specification (GPS) has increasing importance in the machining industry. The tolerancing process should harmonize the relationship between tolerancing, machining process, measuring and design requirements. The aim of the article is to present the interpretation process and the suggested workflow of geometric tolerances. The dimensional and geometric tolerances are compared, and some critical problems of geometric tolerancing are demonstrated by case studies.

Effect of thermal treatments on the surface electrical conductivity of AlSi7Mg produced by laser powder bed fusion

In the last years, the production of hypoeutectic Al-Si waveguide components by metal additive manufacturing has gained increasing attention in the telecommunications industry. The performances of waveguide components are influenced primarily by dimensional tolerances, surface electrical conductivity, surface roughness, and dimensional accuracy. Among these properties, electrical conductivity is known to be strongly influenced by the structural and microstructural characteristics of the alloys.In this work, microstructural and structural properties of an hypoeutectic Al-Si alloy, namely the AlSi7Mg alloy, were studied using FESEM, DSC, and XRD to understand how different thermal treatments (stress relieving, T5, and T6) affect the surface electrical conductivity. In the end, the most suitable thermal treatment to be applied to this alloy to maximize its electrical conductivity and, therefore, its appeal for microwave waveguide components is identified.

Optimization of ultra-precision CBN turning of AISI D2 using hybrid GA-RSM and Taguchi-GRA statistic tools

Ultra-precision turning is a crucial process in the manufacturing industry as it helps to produce parts with high dimensional accuracy, surface finish, and tolerance. The process is similar to traditional turning but is carried out under special circumstances to achieve greater precision and surface finish. The process can be applied to conventional structural materials, but the demand for machining hardened steels is increasing. The optimization of ultra-precision turning of AISI D2 using cubic boron nitride (CBN) tools is a crucial aspect in the field of high-quality machining. This study aims to evaluate the performance of the process and identify the optimal parameters that result in the best quality components while using a CBN tool's ultra-precision turning of AISI D2. Ultra-precision turning process factors such as cutting speed, feed, and depth of cut were experimentally investigated to enhance the response output, such as surface roughness and cutting force components. The full factorial experimental design was used for determining the process characteristics under different conditions, and experimental results were applied to search for the optimum response of machining performance. The optimization process was done by combining the hybrid genetic algorithm-response surface methodology (GA-RSM) and the Taguchi-grey relational analysis (GRA) statistical tools. These methods are useful in situations where the relationship between the input variables and the output responses is complex and non-linear. The results showed that a hybrid GA-RSM approach, combined with Taguchi-GRA statistical analysis, can effectively find optimal process parameters, leading to the best combination of surface roughness and cutting force. In hybrid Taguchi - GRA, the optimal cutting conditions were found to be a cutting speed of 175 m/min, a feed of 0.025 mm, and a depth of cut of 0.06 mm. The findings of this study provide valuable insights for the optimization of ultra-precision CBN turning operations, contribute to the development of precision manufacturing technology, and can be used as a reference for similar machining processes.

Case study using APDMS and RPEMS for SAWL pipes and benefits for offshore pipelay

This paper reviews an Automatic Pipe Dimension Measurement System (APDMS) and a Robotic Pipe End Measurement System (RPEMS) which can measure 19 and 9 parameters with the help of 72 and 6 measurement sensors respectively. APDMS and RPEMS are integrated into one optical measurement system, using laser triangulation, coupled with Systems, Applications and Products in Data Processing (SAP) integration and its own calibration modulus which provides an accurate solution to all pipe measurements. Two longitudinal submerged arc welded offshore projects were executed for an offshore pipe lay with close dimensional tolerances measured using the APDMS for one project and RPEMS for the other project. The radii data, assessed from the newly calculated common centre of all cross-sectional data, was used to line up the two adjacent pipes in a faster and more accurate way. By knowing the shape of the pipe ends based on this radii data, the best relative rotation of these two pipes can be determined and any misalignment will be verified and will stay within the requirements. The extensive database available for each pipe helped to match the line pipes with similar or close out-of-roundness at pipe ends resulting in good fitment of the pipes and ultimately quality welds, together with more pipe joints per day, resulting in a faster completion of the project. This paper shows the significance of using both systems.

Failure analysis of a forming assembly used in aluminum packaging tubes production

A local company produces aluminum collapsible tubes for the packaging of a medicinal ointment. A tooling subassembly comprised of a plug and a sleeve is used for the forming of its metallic neck is failing repeatably; it causes extended downtimes to the production line. Historical data was collected, and macroscopic examination was performed. A photographic archive was created so the substantial features of the incident to be recorded. Hardness measurements were carried out on specific surfaces of the parts and the steel grades selected for their manufacturing were identified by chemical analysis. Samples were designated and prepared for optical and electron microscopy. The study involved the examination of the microstructure and fracture morphologies of the specimens derived from the failed parts. Conclusions related to the fracture mechanism and failure mode are presented. Relatively wide dimensional tolerances between the forming tools led to lack of concentricity between the plug and the sleeve provoking malfunction of the forming process and finally lead to the brittle fracture of the die. Furthermore, the frequency of the plug failure should have been an indication of unsuitable material-working hardness combination. Corrective as well as preventive actions are proposed.

Holistic springback compensation procedure

The elastic springback during the manufacturing process of stamped car body components causes dimensional deviations. To compensate these deviations, the common approach is to modify the tool surfaces in the opposite direction of the deviations – this is called springback compensation. In the procedure of springback compensation various issues must be solved. To achieve the main goal of a dimensionally accurate part, it must be ensured that, on the one hand the distance normal to the sheet surface between the springback part and the target geometry is within a specified dimensional tolerance. On the other hand, it must be ensured that the surface areas and characteristic lengths of the springback part and that of the target geometry match as closely as possible. In the past, approaches/methods, such as the physical compensation method and the physical scaling approach, have been presented which can successfully counteract these problems. Furthermore, in a multi-stage process in subsequent operations a stable part position must be achieved and unwanted plastic deformations must be avoided during blankholder closing. Therefore, different compensation strategies have been presented, which can fulfil these requirements. However, in the publication of these methods, the problems were always considered individually. This paper shows how all the named requirements can be achieved by combining the individual methods in springback compensation.