Digital Twin Paradigm to improve the

Productivity of Machine Tool

DM ZG628T : Dissertation

by

Gireesh Kulkarni

2019HT56007

Dissertation work carried out at

CGTech India Private Limited, Bengaluru

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)

April 2021

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Digital Twin Paradigm to improve the
Productivity of Machine Tool

DM ZG628T: Dissertation

by

Gireesh Kulkarni

2019HT56007

Dissertation work carried out at

CGTech India Private Limited, Bengaluru

Submitted in partial fulfillment of Degree Programme

M.Tech. Digital Manufacturing

Under the Supervision of

Mr. Sujayeendra Jahagirdar, Technical Manager
CGTech India Private Limited, Bengaluru

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)
April 2021

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Annexure C: Format Certificate from the Supervisor

CERTIFICATE

This is to certify that the Dissertation entitled Digital Twin Paradigm to

improve the Productivity of Machine Tool and submitted by Gireesh

Kulkarni having ID-No. 2019HT56007 for the partial fulfillment of the

requirements of M.Tech. Digital Manufacturing degree of BITS, embodies

the bonafide work done by him under my supervision.

______________________

Signature of the Supervisor

Place : Bengaluru

Date : 18-Apr-2021

Mr. Sujayeendra Jahagirdar, Technical Manager

CGTech India Private Limited, Bengaluru

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 Contents

1. Abstract ................................................................................. 5

2. Objectives .............................................................................. 6

3. Introduction to Digital Twin of CNC Machine Tool .................. 6

4. Developing Digital for CNC Machine Tool................................ 7

4.1. Defining the Kinematics tree of Machine Tool ...................... 8

4.2 CAD Modelling the structural components of Machine ....... 10

4.3. Adding the control file for NC Program execution .............. 13

5. Customizing the Control for Special Codes ........................... 14

6. Setting up the Digital Twin (DT) machine for Simulation. .... 15

7. Observations and Results: ................................................... 19

8. Directions for Future Work ................................................... 24

9. Literature References .......................................................... 24

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1. Abstract

Recent developments in digital Manufacturing and ever-increasing global

competitiveness have made the use of virtual simulation tools and collaboration
between the physical and virtual worlds a key factor for quality assurance and
productivity. In this thesis, we examined the development of a simulation and control
system that integrates different aspects that affect machine tool and machining
performance. This holistic approach allows for a better prediction of machining
performance and enhance the productivity and Safety of CNC machine tool.

Most of the of Complex parts machined on CNC machine tool. Different multi-axis CNC
programs prepared generated on CAM platform. These are executed on CNC machine
tool perform the multi-axis machining of complex parts. When Manufacturing
engineering department sends the NC program to CNC machine tool it is not always
100% accurate and safe. Thus generally, machinist not confident on excusing these
programs on 100% speed. This leads to increase in machining and setup time. Also,
sometimes NC programs has errors, thus machinist send back these programs to
Manufacturing department for correction. Thus, the overall machining time get
increased.

In this dissertation we are studying the methods involved in development of Digital

Twin of CNC machine tool. As the Digital integrates all available data and knowledge
seamlessly, it could combine related data to perform accurate simulation-based
forecasting for the production, which allows high level flexibility and safety.

With help of Digital Twin CNC Machine Tool, we are also studying the analyzation of
different Cutting Forces generated during machining with consideration of Work
material properties and Cutting tool geometry. This Force analyze helps us in improving
the Machine tool productivity and enhancing the cutting tool life.

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2. Objectives

• Evaluate the Digital Twin concept in Modern Smart Factories.

• Evaluate the Challenges and benefits of Digital Twin of CNC Machining tool.
• Develop the Digital Twin Paradigm of CNC Machine Tool and perform simulation.
• Predict the potential collision on real machine by using Digital Twin model.
• Compare Cut stock model with Design model and evaluate the result
• Evaluate the productivity improvements with enhanced Digital Twin modules.
• Analyze and Optimize the Machining Force by using Digital Twin Model

3. Introduction to Digital Twin of CNC Machine Tool

A Digital Twin duplicates your CNC Machine and environment inside your Software. A
real Digital Twin is much more than a tool for Simulation. While an accurate kinematic
model of your CNC Machine including travel, limits is important this only shows one
part of a Digital Twin. The digital twin is an important measure to achieve intelligent
manufacturing and industry 4.0. The advancement of DT system in manufacturing
environment is evident. However, current researches in manufacturing domain
concentrated on the discussion of architecture optimization of digital twin system
combining with existing cyber-physics researches.

Machine tool digital twins play an important part in helping machine makers develop
their manufacturing processes. This is because the digital twin allows machine
manufacturers to execute process phases in parallel, which were historically done one
after the other. This has the ability to greatly speed up the whole operation. This is
about the use of digital twins in processing.

For this dissertation we are using application Vericut. Vericut, is a software program
used for CNC machine simulation, verification, and optimization software simulates all
types of CNC machining, additive, and hybrid manufacturing processes. The software
operates independently, but can also be integrated with leading CAM system. It is used
to simulate tool path motion and the material removal process, detecting errors or
areas of inefficiency in NC programs. It was developed by CGTech Inc. and first released
in 1988.

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 4. Developing Digital for CNC Machine Tool

Within the scope of the dissertation, the Digital twin concept was used to develop a
high-speed 5 axis CNC machine from DMG Mori. Following is the picture of Physical and
Digital Twin of CNC machine.

Physical Machine

Digital Twin

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4.1. Defining the Kinematics tree of Machine Tool

All the machine components are established on the Machine Coordinate System (MCS_
it comprises all the physically existing machine axes. Following is picture of simple 3-
axis machine with MCS

The next step is to identify the position of MCS and Number of Kinematics axis for
different machine types. Following are the examples of different machine kinematics.

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Following are the Kinematics of DMG 5-axis machine, which is used for developing the
Digital Twin as the part of dissertation. SINUMERIK 840D is selected are controller for
NC program execution.

The kinematic structure consists of 3 translatory axes in the tool and 2 rotary axes in
the workpiece.

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 After identifying the Kinematic axis, define the two Project Trees in Vericut as below:
1) From Tool to Base
2) From Design to Base
It looks like as below. This will help to ensure the correct movement of Machine
component models. Following are the two trees of this machine.

4.2 CAD Modelling the structural components of Machine

Create the 3D model of different machine axis components by using any CAD
application. Following are the pictures of few machine components.

CAD model of -A- and -C- axis

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CAD model of -Base-

CAD model of -Y- axis

CAD model of -X- axis

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 After creating the CAD model for different axis’s, add it under respective component
of Project tree. Below picture shows CAD model adding for -Base- Component.

Base→ Right click→ Add model→ Model file

Repeat the above steps for all components to add respective models. Next step is to
identify the potential possible collision real machine and define collision table. During
simulation, Vericut will log the collision based on this collision table. Thus, is important
to defile all potential possible collisions in this table. Travel limit can also be added to
identify the error related to over travel limit.

Collision Table setting

Travel Limit setting

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Final Digital Twin of this machine looks as per below picture in Vericut Environment.
Outer enclosure hided to get good visual of internal machine components.

4.3. Adding the control file for NC Program execution

Next step is select the controller for NC program execution. For this machine we select
Sinumeric 840D control. It is available in Vericut library and it can be added as below:

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5. Customizing the Control for Special Codes

a controller is the brain of the CNC machine. In other words, the controller is assigned
with the vital task of interpretation. One of the primary functions of the controller is to
receive conditioned signals from a computer or an indexer. After receiving the signals,
it interprets these signals into mechanical motion. Most of the CNC machine controllers
are customized to meets the geometrical shape or features of the component to be
machined on respective machine.

Following are the most used CNC controllers:

1. FANUC
2. SINUMERIK (SIEMENS)
3. HEIDENHEIN
4. MAZATROL
5. MITSUBISHI
6. FAGOR
7. HASS
8. OKUMA
Controller can be selected based on Number of Axis and CAM software compatibility.

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6. Setting up the Digital Twin (DT) machine for Simulation.

Following data required to configure the DT for simulation and same need to be added to
Vericut Project tree.

• Stock: It can be created by CAD model or Parametric

• Fixture: It can be created by CAD model or Parametric
• Cutting Tools: It can be created by CAD model or Parametric
• Work offset: Location and number of Workoffset
• NC Programs: It should be ISO format
• Design: It can be created by CAD model or Parametric. It used for analysis.

6.1 Stock: It is created by Parametric and added to Project tree.

6.2 Fixture: It is created by CAD Model and it has 6 different components as below:

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6.3 Cutting Tools: This project needs 10 different tools. Below tool created by CAD
model

6.4 Workoffset: This act as origin for NC program execution. Following picture
shows different relation between offsets used in CNC program.

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6.5 NC program: NC program preview as below:

6.6 Design: Created by CAD model and it is used for analysis.

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Following picture shows Work offset position with all components loaded:

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7. Observations and Results:

During simulation following objectives achieved:

7.1 Predict the Material removal without Coolant ON: Following error notify during
simulation.
Removed material with coolant off with tool "mill_surface_80" at line: (38)
N0024 X146.357 M9. Removed volume 152.0576

7.2 Predict the Wrong spindle direction for cutting Tool: Following error notify
during simulation.
Error: Tool spindle spinning in wrong direction for tool "mill_20_r2.5"
loaded in component "Tool"

7.3 Predict the potential collision between Tool and Stock: This is reamer tool
thus, following error notify during simulation.
Error: Reamer Stem of the tool "reamer_d30" loaded in component "Tool"
collided with "Stock" at line (513) N0499 X0. Y0.

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7.4 Predict the potential collision between Machine components: Following error
notify during simulation.
Error: "Tool CUTTER" collided with "C1" at line: (229) y200.

7.5 Predict the potential Travel Limit Error: Following error notify during
simulation.
Error: Component "Z1" exceeded maximum limit of 0.5 by 152.9 at line:
109

7.6 Predict the potential Travel Limit Error: Following error notify during
simulation.
Error: More than one decimal point in an address at line: (80) N0066
Y29.2.68 in file "vericut_the_sample_cam_1_Test01.mpf"

7.7 Predict the Material Removal with RAPID feed rate: Following error notify
during simulation.
Fast feed rate removed material with tool "mill_10_45dg" loaded in
component "Tool" at line: (753) N0736 G0 X20. Y0. D1. Removed volume
4053.7183

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7.8 Compare Cut stock model with Design model and evaluate the result
In AUTO-DIFF we compare a CAD design model to a VERICUT simulation to
automatically detect differences. Using this module, anyone involved in the
production process can identify incorrectly machined areas. AUTO-DIFF is also
used to detect a possible weakness or mistake in the design.

During AUTO-DIFF we can compare both Gouge and Excess Material

Analysis of Excess Material as below:

Analysis of Excess Material as below:

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7.9 Perform Measurements on Simulated part: It can be performed as below:

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 7.10 Predict the Machining Force by using Digital Twin Model
VERICUT Force allows programmers to quickly and easily visualize what is happening
cut-by-cut in the NC program as the tool contacts the material. With VERICUT Force you
clearly see underutilized cutting conditions, excessive forces, metal removal rates,
power, torque, and tool deflections.

Below part taken for Force analysis: Material Titanium-6Al4v

Following is result of Force analysis:

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8. Directions for Future Work

1. Real-time production data can be integrated into digital twinning which can help
boost productivity in manufacturing, allowing businesses to remain competitive
and meet customer demand.
2. Artificial Intelligence (AI) can be embedded for better visualization.
3. Digital Twin capability and leverages a combination of physics-based models and
data-driven analytics to optimize key business indicators such as uptime and
throughput.
4. Digital twins provide engineers with virtual tools that allow them to look at,
explore, and assess physical assets, processes, and systems. With this ability, it is
possible to get an accurate view of what is happening now, as well as what will
happen in the future.
5. With Enhanced Force Analyze and Optimize the Machining time can be reduced
and also Cutting Tool life can be improved.

9. Literature References

1. Digital Twin Driven Smart Manufacturing, Fei Tao, Meng Zhang, and A.Y.C. Nee by
Academic Press
2. Cyber-physical Systems and Digital Twins, Proceedings of the 16th International
Conference on Remote Engineering and Virtual Instrumentation
3. Digital Twin Driven Smart Design, Fei Tao, Meng Zhang, and A.Y.C. Nee by
Academic Press
4. https://www.cgtech.com/products/about-vericut.html
5. https://twincontrol.eu/
6. https://www.home.sandvik/en/stories/articles/2019/07/enabling-digital-
manufacturing/
7. https://iiot-world.com/industrial-iot/connected-industry/the-benefits-of-using-
the-digital-twin-in-manufacturing/
8. https://new.siemens.com/global/en/markets/machinebuilding/machine-
tools/cnc4you/fokus-digitalisierung/digit-twin-rarely-comes-alone.html
9. http://eccmri.com/cgi-bin/

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 Checklist of items for the Final Dissertation Report
This checklist is to be attached as the last page of the report.

This checklist is to be duly completed, verified and signed by the student.

1. Is the final report neatly formatted with all the elements required
Yes
for a technical Report?
2. Is the Cover page in proper format as given in Annexure A? Yes
3. Is the Title page (Inner cover page) in proper format? Yes
4. (a) Is the Certificate from the Supervisor in proper format?
Yes
(b) Has it been signed by the Supervisor?
5. Is the Abstract included in the report properly written within one page?
Yes
Have the technical keywords been specified properly?
6. Is the title of your report appropriate? The title should be adequately
descriptive, precise and must reflect scope of the actual work done. Yes
Uncommon abbreviations / Acronyms should not be used in the title
7. Have you included the List of abbreviations / Acronyms? Yes
8. Does the Report contain a summary of the literature survey? Yes
9. Does the Table of Contents include page numbers?
(i). Are the Pages numbered properly? (Ch. 1 should start on Page # 1)
(ii). Are the Figures numbered properly? (Figure Numbers and Figure
Titles should be at the bottom of the figures)
Yes
(iii). Are the Tables numbered properly? (Table Numbers and Table Titles
should be at the top of the tables)
(iv). Are the Captions for the Figures and Tables proper?
(v). Are the Appendices numbered properly? Are their titles appropriate
10. Is the conclusion of the Report based on discussion of the work? Yes
11. Are References or Bibliography given at the end of the Report?
Have the References been cited properly inside the text of the Report?
Yes
Are all the references cited in the body of the report

12. Is the report format and content according to the guidelines? The report
should not be a mere printout of a Power Point Presentation, or a user
Yes
manual. Source code of software need not be included in the report.

Declaration by Student:
I certify that I have properly verified all the items in this checklist and ensure that the
report is in proper format as specified in the course handout.

Place: Bengaluru Name: Gireesh Kulkarni

Date: 18-Apr-2021 ID No.: 2019HT56007

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