OICC Press Majlesi Journal of Electrical Engineering 2345-3796 14 2 2024 02 15 Design and Development of High-Precision Hybrid Controller for Ultra-Precision Non-Conventional Single-Point Diamond Turning Processes EN Shahrokh Hatefi Ultra-High Precision Manufacturing Laboratory, Department of Mechatronics Engineering, Nelson Mandela University, Port Elizabeth, South Africa. Khaled Abou-El-Hossein Ultra-High Precision Manufacturing Laboratory, Department of Mechatronics Engineering, Nelson Mandela University, Port Elizabeth, South Africa. Journal Article 2024 02 15 Ultra-High precision Single-Point Diamond Turning (SPDT) is a widely used machining technology for generation components with optical grade surfaces. SPDT has been widely used in different industry sectors including aerospace, biomedical, military, defense, electronics, and entertainment. By using SPDT, manufacturing of optical surfaces with roughness down to one nanometer, even less than one nanometer, is possible. Recently, the application of non-conventional SPDT techniques during SPDT for improving the outcome of the process has been emerging. Non-conventional machining techniques have been developed and used during SPDT for assisting the process from different capacities. It has been revealed that by using a sole or a combination of non-conventional techniques during SPDT, superior results in terms of optical surface roughness and surface profile accuracy could be obtained. However, non-conventional SPDT technologies are novel solutions and more research need to be undertaken in terms of optimizing these processes and improving their performance. In this study, a novel high-precision hybrid controller is designed and developed for using in non-conventional SPDT processes. The proposed hybrid controlled has the capability of automatically and precisely control different non-conventional machining techniques during the diamond turning process. This controller could be used in a hybrid SPDT platform for controlling implemented machining techniques and synchronizing them. In addition, this hybrid controller could connect to on-machine metrology devices for in-process data acquisition, analyzing process parameters, and determining machining conditions. Thus, in-process tuning of the working parameters is possible. Results of simulations and experimental study have shown the functionality of the developed controller with sufficient precision to be used in such ultra-precision non-conventional SPDT processes.