Controlling Micrometre-Level Vibrations to Achieve Zero-Defect Manufacturing
In advanced manufacturing, the difference between a high-precision component and a defective one is often measured in just a few micrometres. Diagnosing and correcting these imperfections, caused by machine or process vibrations, is critical to boosting productivity in sectors such as aerospace, transport and energy.
“Surface marks are often below one micrometre, yet they can compromise the functional performance of a bearing or an aerospace engine component,” highlights Dr. Jokin Muñoa, Scientific Director at IDEKO.
To address this issue, the research centre has developed Fast Dressing Servo (FDS), a technology that enables controlled texturing of components through the grinding wheel dressing process. This approach enhances tribological properties, improving lubrication performance and reducing wear and friction by up to 30%.
This methodology replaces costly and poorly repeatable manual processes, such as scraping, with an automated, efficient and ergonomic solution.
In addition, IDEKO has developed the Virtual Vibration Absorber (VVA), an external actuator designed to eliminate forced vibrations in high-precision machines. This ensures that highly demanding sectors such as energy and aerospace can achieve “zero-defect” targets in their components.
Chatter-related challenges
IDEKO will also use its presence at upcoming BIEMH 2026, held from March 2 to 6, to showcase its solutions for diagnosing chatter phenomena and implementing corrective solutions. A boring bar integrating IDEKO’s vibration damping technology will be exhibited as an alternative anti-vibration solution for internal boring and turning operations.
“These processes are characterised by tool dimensions being determined by the geometry of the bore to be machined. This often results in slender tools, which are more prone to developing vibrations,” explains Harkaitz Urreta, Market Director at IDEKO.
The device is capable of mitigating vibrations generated during machining by means of a purpose-designed damper. This damper provides an efficient and cost-effective solution to absorb bar vibrations and can even compensate for stiffness deficiencies in the tool clamping system itself.
IDEKO’s chatter mitigation portfolio is further complemented by the Dynamic Workpiece Stabiliser (DWS) family. This own technology eliminates self-excited vibrations during machining, particularly in flexible components or fixtures with low rigidity – one of the main limiting factors for productivity and quality in material removal processes.
Finally, IDEKO will also present DynAQ at BIEMH, a portable tool combining hardware and software to measure, diagnose and solve vibration-related issues in machines and production equipment, helping to improve efficiency, reliability and availability.
The platform captures signals from multiple sensors, displays their time evolution and performs spectral analysis in a user-friendly way. It has been designed as an intuitive, agile and interactive solution for technical personnel, regardless of their level of expertise in machine dynamics.
For more information: www.ideko.es
