Digital Twin for CNC Machine Tools Design

This paper describes a systematic approach to creating a digital twin, which is focused on the design stage of the product lifecycle of a production machine, considering its operating conditions. To monitor the machine's operating condition in real time, the production machine is linked with a processing environment represented by ANSYS software. The system is demonstrated by evaluating the suitability of the headstock design of a CNC machine tool in terms of stress and strain analysis when it is operated under different performance conditions. First, a model of the machine headstock is created, which is then optimized for FEM calculations with fast response and loading forces obtained from direct dynamometer measurements. It was found that the proposed “design” digital twin approach can be used to optimize other structural elements of production machines based on realistic operating conditions that reflect the operation of machines in different technological sectors.