Case Study for an Operation-based Topology Optimization Using the Digital Twin Approach

Abstract

In order to ensure the mechanical load capability of new products, diverse strength and load analysis methods have to be used while the product design process (e.g. FEA). The main objective of these methods is the predictive analysis of the operational load of the product. Based on this analysis, the structure and the topology of the product can be set adequately in terms of an optimal material utilization and load factor. Nowadays, the mechanical structure analysis can only be done based on estimated loading data, which are determined using approximative theoretical calculation methods. Furthermore, this approach does not consider the actual use and load of the product in the field. As a consequence, inaccurate determination of the material stress and product dimensioning can be accrued in most instances. In order to compensate this incertitude, design engineers set a high safety factor while designing new products, which lead to over-dimensioning of the products and to wasteful use of material and resources. Thanks to powerful sensors, data transmission and data processing technologies, it becomes nowadays easy to collect operating data of technical systems and process and to present and process it using a digital model in real time. This approach is known as digital twin. Using the digital twin concept an integrated and a comprehensive data model as image of real systems and processes with continuously update can be created. This approach opens new prospects within the design process of technical systems in terms of efficiency and sustainability. This paper presents and discusses a case study for the implementation of the digital twin approach in the product design of an arbor press. The aim of this case study is the investigation of the digital twin concept to obtain the material stress and load from the product operation accurately and to use them for material-saving product design.