A digital twin study for immediate design / redesign of impellers and blades: Part 1: CAD modelling and tool path simulation

Abstract

This paper presents a digital twining study conducted for an immediate design / redesign and manufacturing of on impellers & blades. It is by accomplished by developing (i) CAD automation methods, based on the standard modelling procedures and (ii) Manufacturing automation based on the 3/3 + 1/3 + 2/5 axis milling process. Initially, the CAD model of impeller / blade is created by utilizing the dimensional parameters obtained through standard design calculations / data. It is then parametrized and converted to an automated model through simple dimensional rules and geometric algorithms developed for the purpose. After this stage, the CAD model is analyzed for manufacturing automation where the process planning data comprising cutting tools, process parameters and setups are selected. Here, the tool paths are generated for 3/3 + 1/3 + 2/5 axis milling considering a CNC Vertical Machining Center (VMC) to digitally twin milling process. Both the CAD modelling and manufacturing process plans including tool path generation are captured through journaling and customized / improved using the Application Programmable Interface’s (API’s) to suit the present scope. In this paper, the first part on CAD modelling and manufacturing simulation methodologies are discussed through validating the digital twining concept in a virtual environment. The work is developed with the focus to help industries moving towards Industry 4.0 and requiring a constant design improvement in their products. It is by emphasizing the importance of digital twinning concept where a concurrent verification of design and manufacturing process can be achieved.