New Trends in Surface Integrity and Process Optimisation in Ultra-Precision Machining

Ultra-precision machining underpins the manufacture of components where surface quality is not merely aesthetic but functionally critical, from optical lenses and semiconductor wafers to biomedical implants and aerospace parts. As tolerances tighten and material systems grow more complex, understanding and controlling surface integrity — encompassing surface roughness, residual stress, subsurface damage, and microstructural alterations has become a defining challenge of modern precision engineering.This Research Topic brings together experimental, computational, and hybrid investigations into the mechanisms that govern surface integrity in ultra-precision processes, including grinding, lapping, honing, diamond turning, and nanomachining. We seek to capture new trends in the field, highlighting the integration of hybrid manufacturing processes, AI-driven process optimisation, and the deployment of digital twins. It welcomes contributions that advance process optimisation strategies through analytical modelling, molecular dynamics simulation, machine learning-assisted parameter selection, or in-process monitoring and control.Topics of interest include, but are not limited to:o Surface and subsurface damage mechanisms in precision and ultra-precision machiningo Hybrid manufacturing processes and their impact on surface integrityo AI-driven process optimisation and machine learning applications in precision machiningo Digital twins and virtual models for process prediction and surface quality controlo Residual stress prediction and mitigation in ground and turned surfaceso Molecular dynamics and multiscale simulation of material removal at the nano/microscaleo Tool wear and its influence on surface integrityo Process parameter optimisation for improved surface finish and functional performanceo In-process measurement and closed-loop control of surface qualityo Machinability of advanced materials (ceramics, composites, hard alloys, biomaterials)o Sustainable approaches to ultra-precision machining processesThis Research Topic welcomes Original Research, Reviews, and Methods articles. By consolidating advances across simulation, experiment, and process control, it aims to accelerate the translation of precision machining science into industrial practice — particularly in sectors where surface quality directly determines product reliability and longevity. Topic editors: Akinjide Oluwajobi, Tahsin Opoz, Angelos P. Markopoulos Source: https://www.frontiersin.org/research-topics/84435/new-trends-in-surface-integrity-and-process-optimisation-in-ultra-precision-machining