Use of digital tools to simulate the accuracy of subtractive machining processes

The use of Digital tools and IIoT (Industrial Internet of Things) has been a common theme in global research and development over the past decade. This paper describes a newly developed digital environment where the simulation of the machine and machining process can be carried out, with the results indicating the process capability using inspection of a virtual part. By developing high fidelity digital twins of systems using a process that combines pre-calibration and on-machine data captured from both the machine controller and external sensors, it is possible to use a series of mathematical models to simulate the machining process and develop an accurate prediction model of the machined parts. The digital environment combines models of known and predicted geometric and thermal errors. This process can be used to accelerate product and process development without needing to waste valuable production time or precious materials. It can also be used virtually to validate new machine concepts and de-risk high value manufacturing operations, enabling a much more cost effective and sustainable method of manufacturing machine and process design and development. This paper outlines the approach taken to enable the application of the digital tools developed and focuses on the effect of machine geometric errors in a case study. Preliminary validation is achieved by comparing virtual inspection of the virtual part with CMM data for a test part, showing good correlation of typical feature characteristics.