CNC Lathe Modeling and Training to Mitigate Hazard Using Digital Twin

The combination of Virtual Reality (VR) with Digital Twin technology and the Internet of Things (IoT) is revolutionising industrial training through the provision of safe, affordable, and inspiring learning environments. Traditional CNC training procedures face problems such as excessive expenses, risk of safety, and insufficient resources, which push back the skill development process. Our proposed system delivers real-time toolpath simulation, feedback-guided instruction, and synchronized virtual-physical interactions, enabling trainees to practice machining operations in a risk-free environment. IoT data streams and digital twin modelling support predictive diagnostics and process monitoring, while an adaptive learning engine customises training based on user performance. The system was validated using both quantitative performance measures and qualitative feedback from novice operators. Substantial improvements in hazard response time, operating accuracy, and learner interest were observed. Participants found the system realistic, user-friendly, and useful to enhance operating confidence and knowledge.