A New Manufacturing Methodology under Limited Machining Capabilities and Application to High-Performance Hemispherical Resonator

High-performance component production requires nearly homogeneous materials, ultra-precise machining and a high surface integrity. However, conventional design and manufacturing methodologies, which continuously increase the geometric tolerance to meet the performance requirements, lead to cost increases that even exceed the existing machining capabilities. This paper presents a general manufacturing methodology for high-performance components under realistic conditions, such as the current capability for material forming and machining. In order to achieve an excellent component performance, this methodology includes parameter extraction, sensitivity analysis, and trimming processes that consider the effect of material removal resolution and processing uncertainties. Simulations performed on the hemispherical resonator demonstrate how the proposed methodology is applied to fabricate extremely high-performance resonators. An efficient modal tuning strategy is proposed based on a sensitivity analysis of the tuning process parameters subject to material removal resolution and uncertainties. The tuning results prove the feasibility of this new methodology for high-performance components manufacturing. The elimination of the frequency split can finally be achieved with surface tuning iteratively. The proposed methodology provides an effective solution to achieve high-performance components under limited machining capabilities.