Discrete Solid Modeling as Basis of Technological Systems Digital Doubles

The application of CAD/CAM systems as digital doubles at the technological systems elements design stage is the ordinary case. However, such description, based on classical solid-state modeling, has a number of shortcomings: sizes and form idealization, material structure exact information absence, in particular, for composite materials. Thus, the numerical calculation methods of geometry, including voxel, dexel modeling, using representative volume elements, etc. are relevant. However, these and other methods are still applied occasionally to solve special design problems. A wide use of additive technologies allowing generation of product macro-geometry and a microstructure causes need of new approaches application. In this regard, the solution of methodological problems of micro- and macro-modeling simultaneously is an actual problem of engineering process. The paper presents an integrated approach for the description of material structures, in particular of composites, the description of technological system elements in view of errors of their size and a shape, wear, errors of the executive movements and the physical phenomena influencing technological processes. This approach is called discrete solid-state modeling. Its basis is the description of object macro- and micro-geometry as voxel sets and the solution of physical problems using mesh and meshless methods. The examples of modeling tools with a complex surface and assembly parts surface defects and assembly part surface defects modeling are presented.