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The paper aims to use aluminium alloy to substitute steel as the main material of ultra-precision hydro-static bearing system for an ultra-precision plastic electronics production system to lower the manufacturing cost. The total cost of diamond turning and nickel-based electroless coating of an aluminium alloy bearing is expected to be less than the cost of manufacturing a stainless steel bearing.

The paper used a large amount of theoretical calculation to obtain optimal specifications of the bearing system. ANSYS modelling was selected to simulate the deflection of the bearing shaft under high oil pressure. Hundreds of measurements were conducted after the bearing had been manufactured.

The paper provides industrial application insights on using aluminium alloy with a high-quality nickle-based electroless coating as a successful substitution of stainless steel. This created a more economic hydro-static bearing system.

Because of the time limit, different rotational speed tests shall be conducted in the future.

The paper provides implications for the application of nickel-based electroless coating to improve the surface property and bending strength of aluminium alloy, as well as classifying ultra-precision diamond turning as an economic finishing process.

This paper has identified the importance of aluminium alloy with a nickel-based electroless coating as the substitution of stainless steel in a precision hydro-static bearing system.

The purpose of this paper is to show how an ultra‐precision manufacturing process (flycutting) can be improved through interferometry.

The paper presents a theoretical model of the machine tool cutting system and then uses interferometer measurements to validate the results. The model is then used to show some general findings relating process conditions to workpiece quality.

A realistic cutting model can predict the workpiece flatness with excellent accuracy and closely match interferometer measurements. The process parameters in precision flycutting should be chosen such that the flycutting tool is in contact with the workpiece for an integer number of vibration cycles. The machine tool stiffness and structural damping will affect the workpiece quality, but the most significant improvements are made through thoughtful selection of the flycutter spindle speed as it relates to the machine dynamics.

This paper presents a math model that accurately matches results obtained by experimental verification and extensive testing. Interferometry is shown to be an extremely useful tool in optimizing the process conditions in a flycutting manufacturing operation. Furthermore, the results are of general use to practitioners using flycutting in a variety of industrial applications.