Recently, the research team led by Prof. Liu Zhanqiang and Prof. Wang Bing from the School of Mechanical Engineering achieved significant progress in smart ultra-precision machining systems towards fabrication of equipment components operating under extreme service conditions. The relevant research, entitled “Smart ultra-precision machining system integrated with online monitoring of machined surface profile accuracy and real-time error compensation,” was presented at the 2026 ASME Manufacturing Science and Engineering Conference and the 54th SME’s North American Manufacturing Research Conference (MSEC 2026 & NAMRC 54), and was also published in Journal of Manufacturing Systems.

The corresponding author of the paper is Prof. Wang Bing, and the first author is Li Honglu, a PhD student at Shandong University. Other co-authors include Prof. Liu Zhanqiang and Associate Research Fellow Zhao Jinfu from Shandong University, and Assistant Prof. Wang Pengyang from the University of Macau.

Ultra-precision machining is a key enabling technology for fabricating functional microstructure surfaces, which can achieve sub-micrometer form accuracy and nanometer-scale surface roughness. It plays an important role in high-end manufacturing fields such as aerospace, precision optics, and advanced equipment operating under extreme service conditions. For these components, surface topography and profile accuracy directly determine functional performance and reliability. However, ultra-precision machining is affected by multiple coupled error sources, including machine tool motion errors, deformation of the workpiece material, tool related errors, and environmental disturbances. These errors ultimately appear on the machined surface, making real-time accuracy monitoring and control a widely recognized frontier challenge in the field.

In this work, the research team developed a smart ultra-precision machining system that integrates online sensing of machined surface profile accuracy and real-time compensation of machining errors. The team established a quantitative relationship between ultra-precision machining parameters and cutting force signals, while a tool path reconstruction method based on real-time cutting force sensing was proposed and a digital twin framework for three-dimensional surface generation of machined microstructures in ultra-precision cutting was developed. By using cutting force deviation as feedback, the system enables intelligent monitoring of machined surface profile accuracy and real-time error compensation. Experimental results show that the profile error of representative microstructure components can be controlled within 50 nm. The research can provide technical foundation and equipment support for improving the machining accuracy of key components used in equipment operating under extreme service conditions.

Based on this work, Prof. Wang Bing was invited to attend MSEC 2026 & NAMRC 54 and delivered a presentation on the research. He also served as chair of the “Manufacturing Systems” session at the conference.

In recent years, the team led by Prof. Liu Zhanqiang and Prof. Wang Bing has made a series of significant advances in ultra-high-speed and ultra-precision cutting processes and equipment technology. Their related research has been published in leading international journals, including International Journal of Machine Tools and Manufacture, Journal of Manufacturing Systems, IEEE Transactions journals, and CIRP Annals.

This research was supported by the National Key Research and Development Program of China, the Young Scientists Fund (Category B) of the National Natural Science Foundation of China, the National Science and Technology Major Project on High-end CNC Machine Tools and Basic Manufacturing Equipment, and the Major Basic Research Project of Shandong Provincial Natural Science Foundation.