Catálogo de publicaciones - libros

This section focusses on the dynamic modelling of the machine tool including its computer numeric control, and its interaction with the machining process. To properly simulate modern machine tools in machining condition, the virtual machine tool model based on SAMCEF Mecano is used to account for close interaction between the dynamic behaviour of the mechanical structure, drives and the control. To fully capture the dynamic behaviour of the machine, force interactions between the cutting tool and the workpiece are also considered. A strong coupling between the mechatronic model of the machine tool and a machining simulation tool is implemented. A specialized cutting force element has been developed. It considers the dynamics of the tooltip combined with the tool-workpiece engagement to generate cutting forces. The use of such digital twin model is demonstrated considering some machining operations.

Machining process is set-up in the machines at different levels of maturity. While in large batch manufacturing, a long time is spent in process design and optimization, and in small batch production, the process design time is limited, and the designed process is far to be optimized. In any case, the possibility to control and optimize the process at machine level is very important to increase the productivity. The concept of cyber-physical systems (CPS) is introduced in this paper to increase machine tool performance and process productivity. Several CPS-based features developed in Twin-Control are presented.

Fleet-wide proactive maintenance characterizes all services that are made available to the users to help them to operate, supervise and maintain a fleet of systems. These services can be, for a general manager of a fleet, a dashboard of all the systems’ business indicators or, for a technical manager, a dashboard of all the systems’ maintenance and health status. At the bottom level of the pyramidal hierarchy, a technical operator should have a fast overview of the systems’ status and should be alerted at the right time when a system needs to be checked. Nowadays, more and more data and information are available on machine tools which should be treated and analysed to extract the right information for the right people at the right time. To achieve this goal, a fleet-wide proactive maintenance platform requires several main business services to have an understandable view of the system by all users and, thus, save time for decision-making during diagnosis and prognosis analysis.

Although process monitoring can facilitate to detect deviations from required part quality and safe process conditions, the analysis and postprocessing of the measured data are not embedded into the CAx workflow. Binding the measurement data together with material removal simulation creates a powerful tool for CAM programmers and process engineers. The user can analyze 3D visualization of the machining process more intuitively. A developed CAM integration simulates material removal considering the actual tool coordinates (measured during the process) and can depict the acquired and simulated cutting conditions (spindle torque, axes accelerations, etc.) with various color schemes on in-process stock simulation.

More and more ICT applications appear in both market and research world, but few of them are applied under industrial conditions. One of the highlights of Twin-Control project is the validation of the different features in industrial environments. To do that, two validation scenarios, with very different requirements were defined. In this chapter, the evaluation of Twin-Control in an aerospace use case is presented. The evaluation consists in the presentation of the different implementations and the obtained results, as well as the impact caused by them in the end-users. This document shows the benefits of the application of Twin-Control in such a demanding sector like aerospace.

This chapter presents the evaluation of Twin-Control in an automotive validation scenario consisting in the production line of a RENAULT electrical motor component that is composed by three COMAU machine tools. Automotive industry requires very optimized and controlled machining process, due to large batches and tight margin cost. In addition, life-cycle features like energy consumption and maintenance costs are of special relevance. The evaluation covers the different stages of the product developing cycle. This document highlights different obtained results of the implementation of Twin-Control features and their impact. Great benefits are provided to the industrial end-users.