Abstract
This paper presents a further elaboration of the use of the digital twin concept in digital machining. The main goal of the research is an attempt to combine digital representations of different objects involved in the machining process in a holistic manner. Digital twins of the in-process workpiece, cutting tool, clamping, and machine tool along with the process twin are connected in a framework in which all these elements can influence each other. The framework shows different levels of integration of different digital twins and practical recommendation on the implementation. Besides, the framework supports a simulation layer that provides data for the intensity of the interaction. Such interactions can result in, for instance, cascading calculations of cutter workpiece engagement, cutting forces, tool wear, tool deflection, chatter, and so on. Eventually, a design for a software mockup was elaborated to present the developed framework. The entire workflow to simulate part machining in such a digital representation can be used as an ultimate tool for CAM simulation and NC verification within the Zero Defect Manufacturing paradigm.
Highlights
The concept of the Digital Twins gets more and more traction in the manufacturing industry
No one is identical to another because there are always variations in the material properties, process parameters, etc. These differences cannot be foreseen by the classical CAM simulation, which is often believed to be a kind of a digital twin
Each pixel on the cutting tool may keep the history of all tool moves in which the pixel was in the cutter workpiece engagement (CWE), spindle speeds, feeds commanded, and the duration of the moves
Summary
The concept of the Digital Twins gets more and more traction in the manufacturing industry. No one is identical to another because there are always variations in the material properties, process parameters, etc These differences cannot be foreseen by the classical CAM simulation, which is often believed to be a kind of a digital twin. Monitoring-based simulation can acquire real values of machine axes and use them in CAM simulation This approach results in a more genuine NC verification ([Armendia 2019], [Plakhotnik 2019], and [Zhao 2019]). Depending on the focus of the research or practical interests, the core element of the digital twin can be either a cutting tool or machine. [Botkina 2018] elaborated a data format and data management for a digital twin of the cutting tool to trace data about the tool’s ongoing machining operation, toolpath, forces and torques, time of usage, etc.
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