Ultrasonic vibration has been employed to assist in turning, introducing intermittent machining to reduce average cutting force, minimize tool wear, and enhance machining efficiency, thereby improving surface roughness. However, achieving intermittent cutting necessitates specific conditions, with a cutting speed or feed rate falling below the critical speed associated with the ultrasonic vibration parameters. This study presents a theoretical model for surface formation in cutting-speed-direction ultrasonic-assisted turning (CUAT), covering both continuous and intermittent machining regimes. Experimental validation was conducted on C45 carbon steel and 201 stainless steel to demonstrate the applicability of the theoretical model across different materials. Digital microscope analysis revealed 3D topography consistency with the theoretical formula. Surface roughness evaluations were performed for both CUAT and CT (conventional turning) methods. The results indicated a significant reduction in roughness Ra for C45 steel samples machined with CUAT, up to 80% compared to CT at a cutting speed of 20 m/min, while only exhibiting slight fluctuations when turning 201 stainless steel. Detailed analysis and explanation of these phenomena are presented herein.

High-speed data acquisition systems based on field-programmable gate arrays (FPGAs) often face synchronization challenges when interfacing with commercial analog-to-digital converters (ADCs), particularly under constrained hardware routing conditions and vendor-specific clocking assumptions. This work presents a vendor-independent FPGA–ADC synchronization architecture that enables reliable and repeatable high-speed data acquisition without relying on clock-capable input resources. Clock and frame signals are internally reconstructed and phase-aligned within the FPGA using mixed-mode clock management (MMCM) and input serializer/deserializer (ISERDES) resources, enabling time-sequential phase observation without the need for parallel snapshot or delay-line structures. Rather than targeting absolute metrological limits, the proposed approach emphasizes a reproducible and transparent data acquisition methodology applicable across heterogeneous FPGA–ADC platforms, in which clock synchronization is treated as a system-level design parameter affecting digital interface timing integrity and data reproducibility. Experimental validation using a custom Kintex-7 (XC7K325T) FPGA and an AFE7225 ADC demonstrates stable synchronization at sampling rates of up to 125 MS/s, with frequency-offset tolerance determined by the phase-tracking capability of the internal MMCM-based alignment loop. Consistent signal acquisition is achieved over the 100 kHz–20 MHz frequency range. The measured interface level timing uncertainty remains below 10 ps RMS, confirming robust clock and frame alignment. Meanwhile, the observed signal-to-noise ratio (SNR) performance, exceeding 80 dB, reflects the phase–noise-limited measurement quality of the system. The proposed architecture provides a cost-effective, scalable, and reproducible solution for experimental and research-oriented FPGA-based data acquisition systems operating under practical hardware constraints.

In this paper, a novel, compact, and high-precision axial error measurement using a frequency-modulated interferometer is developed. Normally, heterodyne interferometers are a powerful system for small displacement measurements due to their property of being less sensitive to temperature and pressure variations. However, the maximum measurement speed of the heterodyne interferometer is around 5 m/s because it is usually limited by the difference in frequency between the two components of the laser beam, which is no larger than 3 MHz or 20 MHz corresponding laser source based on the Zeeman effect and acousto-optic modulator, respectively. The proposed measuring system is realized by modulating the frequency of the laser diode source at a high modulation frequency and using lock-in amplifiers to extract the harmonics of the interference signal. The measurement speed is proportional to the modulation frequency. Thus, the higher the modulation frequency, the higher the measuring speed attains. The frequency-modulated interferometer is then applied to measure the axial error of an ultra-precision spindle. The proposed system can be a capable solution for noncontact and high-precision spindle error measurements in the machining process.

The measurement speed and measurement accuracy of a displacement measuring interferometer are key parameters. To verify these parameters, a fast and high-accuracy motion is required. However, the displacement induced by a mechanical actuator generates disadvantageous features, such as slow motion, hysteresis, distortion, and vibration. This paper proposes a new method for a nonmechanical high-speed motion using an electro-optic modulator (EOM). The method is based on the principle that all displacement measuring interferometers measure the phase change to calculate the displacement. This means that the EOM can be used to accurately generate phase change rather than a mechanical actuator. The proposed method is then validated by placing the EOM into an arm of a frequency modulation interferometer. By using two lock-in amplifiers, the phase change in an EOM and, hence, the corresponding virtual displacement could be measured by the interferometer. The measurement showed that the system could achieve a displacement at 20 kHz, a speed of 6.08 mm/s, and a displacement noise level < 100 pm//√Hz above 2 kHz. The proposed virtual displacement can be applied to determine both the measurement speed and accuracy of displacement measuring interferometers, such as homodyne interferometers, heterodyne interferometers, and frequency modulated interferometers.