Digital Twin Modeling Enabled Machine Tool Intelligence:A Review

Machine tools,often referred to as the“mother machines”of the manufacturing industry,are crucial in developing smart manufacturing and are increasingly becoming more intelligent.Digital twin technology can promote machine tool intelligence and has attracted considerable research interest.However,there is a lack of clear and systematic analyses on how the digital twin technology enables machine tool intelligence.Herein,digital twin modeling was identified as an enabling technology for machine tool intelligence based on a comparative study of the characteristics of machine tool intelligence and digital twin.The review then delves into state-of-the-art digital twin modelingenabled machine tool intelligence,examining it from the aspects of data-based modeling and mechanism-data dual-driven modeling.Additionally,it highlights three bottleneck issues facing the field.Considering these problems,the architecture of a digital twin machine tool(DTMT)is proposed,and three key technologies are expounded in detail:Data perception and fusion technology,mechanism-data-knowledge hybrid-driven digital twin modeling and virtual-real synchronization technology,and dynamic optimization and collaborative control technology for multilevel parameters.Finally,future research directions for the DTMT are discussed.This work can provide a foundation basis for the research and implementation of digital-twin modeling-enabled machine tool intelligence,making it significant for developing intelligent machine tools.

Geometric Error Identification of Gantry-Type CNC Machine Tool Based on Multi-Station Synchronization Laser Tracers

Laser tracers are a three-dimensional coordinate measurement system that are widely used in industrial measurement.We propose a geometric error identification method based on multi-station synchronization laser tracers to enable the rapid and high-precision measurement of geometric errors for gantry-type computer numerical control(CNC)machine tools.This method also improves on the existing measurement efficiency issues in the single-base station measurement method and multi-base station time-sharing measurement method.We consider a three-axis gantry-type CNC machine tool,and the geometric error mathematical model is derived and established based on the combination of screw theory and a topological analysis of the machine kinematic chain.The four-station laser tracers position and measurement points are realized based on the multi-point positioning principle.A self-calibration algorithm is proposed for the coordinate calibration process of a laser tracer using the Levenberg-Marquardt nonlinear least squares method,and the geometric error is solved using Taylor’s first-order linearization iteration.The experimental results show that the geometric error calculated based on this modeling method is comparable to the results from the Etalon laser tracer.For a volume of 800 mm×1000 mm×350 mm,the maximum differences of the linear,angular,and spatial position errors were 2.0μm,2.7μrad,and 12.0μm,respectively,which verifies the accuracy of the proposed algorithm.This research proposes a modeling method for the precise measurement of errors in machine tools,and the applied nature of this study also makes it relevant both to researchers and those in the industrial sector.

Numerical Investigation of Thermal Behavior of CNC Machine Tool and Its Effects on Dimensional Accuracy of Machined Parts

The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally induced positioning error compensation remains the most effective and practical method in this context. However, the efficiency of the compensation process depends on the quality of the model used to predict the thermal errors. The model should consistently reflect the relationships between temperature distribution in the MT structure and thermally induced positioning errors. A judicious choice of the number and location of temperature sensitive points to represent heat distribution is a key factor for robust thermal error modeling. Therefore, in this paper, the temperature sensitive points are selected following a structured thermomechanical analysis carried out to evaluate the effects of various temperature gradients on MT structure deformation intensity. The MT thermal behavior is first modeled using finite element method and validated by various experimentally measured temperature fields using temperature sensors and thermal imaging. MT Thermal behavior validation shows a maximum error of less than 10% when comparing the numerical estimations with the experimental results even under changing operation conditions. The numerical model is used through several series of simulations carried out using varied working condition to explore possible relationships between temperature distribution and thermal deformation characteristics to select the most appropriate temperature sensitive points that will be considered for building an empirical prediction model for thermal errors as function of MT thermal state. Validation tests achieved using an artificial neural network based simplified model confirmed the efficiency of the proposed temperature sensitive points allowing the prediction of the thermally induced errors with an accuracy greater than 90%.

Further Analysis of Machine Tool Dimensional Accuracy and Thermal Stability under Varying Floor Temperature

Machining is as old as humanity, and changes in temperature in both the machine’s internal and external environments can be of great concern as they affect the machine’s thermal stability and, thus, the machine’s dimensional accuracy. This paper is a continuation of our earlier work, which aimed to analyze the effect of the internal temperature of a machine tool as the machine is put into operation and vary the external temperature, the machine floor temperature. Some experiments are carried out under controlled conditions to study how machine tool components get heated up and how this heating up affects the machine’s accuracy due to thermally induced deviations. Additionally, another angle is added by varying the machine floor temperature. The parameters mentioned above are explored in line with the overall thermal stability of the machine tool and its dimensional accuracy. A Robodrill CNC machine tool is used. The CNC was first soaked with thermal energy by gradually raising the machine floor temperature to a certain level before putting the machine in operation. The machine was monitored, and analytical methods were deplored to evaluate thermal stability. Secondly, the machine was run idle for some time under raised floor temperature before it was put into operation. Data was also collected and analyzed. It is observed that machine thermal stability can be achieved in several ways depending on how the above parameters are joggled. This paper, in conclusion, reinforces the idea of machine tool warm-up process in conjunction with a carefully analyzed and established machine floor temperature variation for the approximation of the machine tool’s thermally stability to map the long-time behavior of the machine tool.

Research on Machine Tool Fault Diagnosis and Maintenance Optimization in Intelligent Manufacturing Environments

In the context of intelligent manufacturing,machine tools,as core equipment,directly influence production efficiency and product quality through their operational reliability.Traditional maintenance methods for machine tools,often characterized by low efficiency and high costs,fail to meet the demands of modern manufacturing industries.Therefore,leveraging intelligent manufacturing technologies,this paper proposes a solution optimized for the diagnosis and maintenance of machine tool faults.Initially,the paper introduces sensor-based data acquisition technologies combined with big data analytics and machine learning algorithms to achieve intelligent fault diagnosis of machine tools.Subsequently,it discusses predictive maintenance strategies by establishing an optimized model for maintenance strategy and resource allocation,thereby enhancing maintenance efficiency and reducing costs.Lastly,the paper explores the architectural design,integration,and testing evaluation methods of intelligent manufacturing systems.The study indicates that optimization of machine tool fault diagnosis and maintenance in an intelligent manufacturing environment not only enhances equipment reliability but also significantly reduces maintenance costs,offering broad application prospects.

On dry machining of AZ31B magnesium alloy using textured cutting tool inserts

Magnesium alloys have many advantages as lightweight materials for engineering applications,especially in the fields of automotive and aerospace.They undergo extensive cutting or machining while making products out of them.Dry cutting,a sustainable machining method,causes more friction and adhesion at the tool-chip interface.One of the promising solutions to this problem is cutting tool surface texturing,which can reduce tool wear and friction in dry cutting and improve machining performance.This paper aims to investigate the impact of dimple textures(made on the flank face of cutting inserts)on tool wear and chip morphology in the dry machining of AZ31B magnesium alloy.The results show that the cutting speed was the most significant factor affecting tool flank wear,followed by feed rate and cutting depth.The tool wear mechanism was examined using scanning electron microscope(SEM)images and energy dispersive X-ray spectroscopy(EDS)analysis reports,which showed that at low cutting speed,the main wear mechanism was abrasion,while at high speed,it was adhesion.The chips are discontinuous at low cutting speeds,while continuous at high cutting speeds.The dimple textured flank face cutting tools facilitate the dry machining of AZ31B magnesium alloy and contribute to ecological benefits.

ArcCHECK Machine QA工具在医用直线加速器质量保证中的应用效果

目的探讨ArcCHECK Machine QA工具在医用直线加速器质量保证中的应用效果。方法利用ArcCHECK Machine QA工具和ArcCHECK体模对医用直线加速器进行性能测试,项目包括机架角度、机架旋转速度、机架旋转中心、多叶准直器和铅门位置的一致性、机架旋转出束时的平坦度和对称性,评估该工具在医用直线加速器质量保证中的应用效果。结果旋转模式下机架平均旋转速度为3.6 deg/s,最大偏差约0.5 deg/s;机架旋转等中心形成的平均半径为0.4 mm,多叶准直器与铅门的最大距离正、负差异平均值分别为0.7 mm、-0.7 mm;旋转出束模式下Y方向的平坦度为1.8%,Y方向的对称性为1.1%,X方向的对称性为4.3%。结论ArcCHECK Machine QA工具可用于医用直线加速器常规及容积调强出束性能质量保证。

Spatial Expression of Assembly Geometric Errors for Multi-axis Machine Tool Based on Kinematic Jacobian-Torsor Model

Assembly geometric error as a part of the machine tool system errors has a significant influence on the machining accuracy of the multi-axis machine tool.And it cannot be eliminated due to the error propagation of components in the assembly process,which is generally non-uniformly distributed in the whole working space.A comprehensive expression model for assembly geometric error is greatly helpful for machining quality control of machine tools to meet the demand for machining accuracy in practice.However,the expression ranges based on the standard quasistatic expression model for assembly geometric errors are far less than those needed in the whole working space of the multi-axis machine tool.To address this issue,a modeling methodology based on the Jacobian-Torsor model is proposed to describe the spatially distributed geometric errors.Firstly,an improved kinematic Jacobian-Torsor model is developed to describe the relative movements such as translation and rotation motion between assembly bodies,respectively.Furthermore,based on the proposed kinematic Jacobian-Torsor model,a spatial expression of geometric errors for the multi-axis machine tool is given.And simulation and experimental verification are taken with the investigation of the spatial distribution of geometric errors on five four-axis machine tools.The results validate the effectiveness of the proposed kinematic Jacobian-Torsor model in dealing with the spatial expression of assembly geometric errors.

Machines,Tools and Tool Transporter Concurrent Scheduling in Multi⁃machine FMS with Alternative Routing Using Symbiotic Organisms Search Algorithm

This study explored the concurrent scheduling of machines, tools, and tool transporter(TT) with alternative machines in a multi-machine flexible manufacturing system(FMS), taking into mind the tool transfer durations for minimization of the makespan(MSN). When tools are expensive, just a single copy of every tool kind is made available for use in the FMS system. Because the tools are housed in a central tool magazine(CTM), which then distributes and delivers them to many machines, because there is no longer a need to duplicate the tools in each machine, the associated costs are avoided. Choosing alternative machines for job operations(jb-ons), assigning tools to jb-ons, sequencing jb-ons on machines, and arranging allied trip activities, together with the TT’s loaded trip times and deadheading periods, are all challenges that must be overcome to achieve the goal of minimizing MSN. In addition to a mixed nonlinear integer programming(MNLIP) formulation for this simultaneous scheduling problem, this paper suggests a symbiotic organisms search algorithm(SOSA) for the problem’s solution. This algorithm relies on organisms’ symbiotic interaction strategies to keep living in an ecosystem. The findings demonstrate that SOSA is superior to the Jaya algorithm in providing solutions and that using alternative machines for operations helps bring down MSN.

Energy-Efficient Approaches for a Machine Tool Building in a University through Field Measurement and Energy Modelling

The heating,ventilating,and air conditioning(HVAC)system consumes nearly 50%of the building’s energy,especially in Taiwan with a hot and humid climate.Due to the challenges in obtaining energy sources and the negative impacts of excessive energy use on the environment,it is essential to employ an energy-efficient HVAC system.This study conducted the machine tools building in a university.The field measurement was carried out,and the data were used to conduct energymodelling with EnergyPlus(EP)in order to discover some improvements in energy-efficient design.The validation between fieldmeasurement and energymodelling was performed,and the error rate was less than 10%.The following strategies were proposed in this study based on several energy-efficient approaches,including room temperature settings,chilled water supply temperature settings,chiller coefficient of performance(COP),shading,and building location.Energy-efficient approaches have been evaluated and could reduce energy consumption annually.The results reveal that the proposed energy-efficient approaches of room temperature settings(3.8%),chilled water supply temperature settings(2.1%),chiller COP(5.9%),using shading(9.1%),and building location(3.0%),respectively,could reduce energy consumption.The analysis discovered that using a well-performing HVAC system and building shading were effective in lowering the amount of energy used,and the energy modelling method could be an effective and satisfactory tool in determining potential energy savings.

An Optimal Feed Interpolator Based on G^2 Continuous Bézier Curves for High-Speed Machining of Linear Tool Path

A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments.

High-Speed Permanent Magnet Electrical Machines - Applications, Key Issues and Challenges

In this paper,application examples of high-speed electrical machines are presented,and the machine structures are categorized.Key issues of design and control for the high-speed permanent magnet machines are reviewed,including bearings selection,rotor dynamics analysis and design,rotor stress analysis and protection,thermal analysis and design,electromagnetic losses analysis and reduction,sensorless control strategies,as well as comparison and selection of sine-wave and square-wave drive modes.Some challenges are also discussed,so that future studies could be focused.

Calculation for Stator Loss of High-Speed Permanent Magnet Synchronous Machine in Torque-speed Envelope and Restraint Approach for Circulating Current in Windings

Iron loss and copper loss are the significant parts of electrical loss of machines,which are the major parts particularly under high frequency condition.High-speed permanent magnet synchronous machines(HS-PMSM)have the benefits of high power density,high efficiency and wide speed range.Which causes the calculation for iron loss and copper loss in whole operating range complex.By analyzing the components and influencing factors of iron loss and copper loss in stator,we have deduced the calculation formula of iron loss and copper loss in whole operating range based on the analytical solution and finite element approach(EFA)solution.According to the calculation solution,taking the influence of operating temperature on the iron loss and copper loss into account,we propose a temperature correction factor and establish the calculation method for the iron loss and copper loss with temperature influences.Finally,by the conductor transposition,we restrain the circulating current under high-frequency operating condition.

Tool-path planning for free-form surface high-speed high-resolution machining using torus cutter

In CNC machining, two essential components decide the accuracy and machining time for a sculptured surface: one is the step-size interval, the other is the tool-path interval. Due to the limitation of the conventional method for calculating the tool-path interval, it cannot satisfy the machining requirement for high-speed and high-resolution machining. Accordingly, for high-speed and high-resolution machining, the current study proposes a new tool-path interval algorithm, plus a variable step-size algorithm for NURBS. Furthermore, a new type cutter, which can improve the cutting efficiency, is investigated in the paper. The transversal equation of the torus cutter onto the flat plan is given in this paper. The tool-path interval is calculated with the transversal equation and the proposed algorithm. The illustrated example shows that the redundant tool paths can be reduced because an accurate tool-path interval could be calculated.

Development and Application of Complete Equipment for High-speed Tunnel Boring and Bolting Machines

With the improvement of coal mining speed and mechanization level in China,traditional tunnel boring methods can no longer meet the actual needs.In order to solve the problems of low efficiency,high labor intensity,slow tunnel boring speed,bad working environment and poor safety in traditional tunnel boring,on the basis of analyzing the development and application of coal roadway tunnel boring equipment at home and abroad,complete equipment for high-speed tunnel boring and bolting machines was developed by using the integrated technology of tunnel boring and bolting.The complete equipment for high-speed tunnel boring and bolting machines has the functions of tunnel boring and bolting synchronization,once-tunneling,negative pressure dust removal,digital guidance,independent cutting feed,digital cutting,safety monitoring and data interaction,which has the advantages of safety in use,reliability and efficiency.

Continuous prediction method of earthquake early warning magnitude for high-speed railway based on support vector machine

Purpose–Using the strong motion data ofK-net in Japan,the continuous magnitude prediction method based on support vector machine(SVM)was studied.Design/methodology/approach–In the range of 0.5–10.0 s after the P-wave arrival,the prediction time window was established at an interval of 0.5 s.12 P-wave characteristic parameters were selected as the model input parameters to construct the earthquake early warning(EEW)magnitude prediction model(SVM-HRM)for high-speed railway based on SVM.Findings–The magnitude prediction results of the SVM-HRM model were compared with the traditional magnitude prediction model and the high-speed railway EEW current norm.Results show that at the 3.0 s time window,themagnitude prediction error of the SVM-HRMmodel is obviously smaller than that of the traditionalτc method and Pd method.The overestimation of small earthquakes is obviously improved,and the construction of the model is not affected by epicenter distance,so it has generalization performance.For earthquake events with themagnitude range of 3–5,the single station realization rate of the SVM-HRMmodel reaches 95%at 0.5 s after the arrival of P-wave,which is better than the first alarm realization rate norm required by“The TestMethod of EEW andMonitoring Systemfor High-Speed Railway.”For earthquake eventswithmagnitudes ranging from3 to 5,5 to 7 and 7 to 8,the single station realization rate of the SVM-HRM model is at 0.5 s,1.5 s and 0.5 s after the P-wave arrival,respectively,which is better than the realization rate norm of multiple stations.Originality/value–At the latest,1.5 s after the P-wave arrival,the SVM-HRM model can issue the first earthquake alarm that meets the norm of magnitude prediction realization rate,which meets the accuracy and continuity requirements of high-speed railway EEW magnitude prediction.

TOOL WEAR PATTERNS AND MECHANISMS OF SOLID CEMENTED CARBIDE IN HIGH-SPEED MILLING OF ALUMINUM ALLOY

The wear patterns and wear mechanisms of solid cemented carbide are analyzed in high-speed milling of aluminum alloy. Results show that the dominant wear patterns are coating damage, crater wear, micro-chipping, breakage, and so on. The main wear mechanisms are adhesion, diffusion and fatigue. Compared with conventional speed machining, the effect and impact of thermal-dynamical coupling field play an important role in the cutting tool wear in high-speed milling of aluminum alloy.

Simulation Study of the Workspace of the Parallel Machine Tool

A new three dimensional simulation method is introduced to study the workspace of a 6 PSS (P denotes a prismatic kinematic pair, S denotes a spherical kinematic pair) parallel machine tool. This algorithm adopts the method of numerical analysis to investigate the boundary points in a series of sections which form the surface of the workspace. That is, to study such points that have the largest polar radius on a certain section in a system of polar coordinates according to conditions of constraint. The constraint conditions considered in the article include the maximum and minimum displacements of each dieblock, the maximum and minimum angles of oscillation in each hinge. By converting the constraint inequalities into constraint equations, the largest polar radius corresponding to every constraint condition can be evaluated and the minimum one is used to decide the boundary point. This algorithm greatly simplifies the computational process and can be used to analyze any section of the workspace. It provides a theoretical basis for the structural design of such a machine tool.

METHOD FOR SUPPRESSING CUTTING CHATTER IN NUMERICAL CONTROL MACHINE TOOLS

A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.

STUDY ON THE COMPENSATION TECHNIQUE OF POSITIONING ERRORS FOR NC MACHINE TOOLS

Through analysis of the basic transformation of a typical body,the error transformations of the position vector and the displacement vector are employed,a general model for positioning errors of NC machine tools by using kinematics of the multi body system is discussed.By means of 8031 single chip system,intelligent error compensation controller has been developed.The results of experiments on XH714 machining center show that the positioning accuracy is enhanced effectively by more than 50%.