Investigation on digital twin of the ultraprecision machining system for manufacturing freeform surfaced components

Abstract Digital Twin (DT) is widely regarded as the future for advanced engineering manufacture, addresses the critical challenge for continuous improvement and optimization of manufacturing systems through real-time machining process monitoring, in-process diagnosis and dynamic process optimization, and digital and physical data fusion for higher manufacturing precision. Therefore, developing a DT for the ultraprecision manufacturing (UPM) system is inevitably essential for future generation UPM systems and machines. In this paper, an investigation on digital twin of the ultraprecision machining system and its implementation perspectives are presented particularly against the ever-increasing demand for higher precision machining accuracy, e.g. the increasingly more stringent requirement in manufacturing freeform surfaced components and devices. The investigation is focused on the kinematics and dynamics modelling of the machining system (as the foundation of the DT development), the DT implementation, and the application case study, which reflects the innovative attempt on seamless integration of ultraprecision machining fundamentals, innovative development of applied DT technology, and high value ultraprecision applications. Design, manufacturing and control, combined with computationally efficient DT design and optimization algorithms will lead to the higher form/dimensional accuracy and finer surface roughness of the ultraprecision components/parts, in a competitive and promising industrial manner.