Cutting model integrated digital twin–based process monitoring in small-batch machining

The success of machining process automation hinges primarily on the effectiveness of the monitoring and adaptive control systems. A new digital twin–based process monitoring method and system in small batch machining is presented, and the cutting model is integrated into the monitoring method to improve the diagnosis accuracy. Model-based and signal-based monitoring indicators are developed, and indicators of the residual force component for the tool wear monitoring and energy ratio for the chatter detection are introduced to the digital twin–based monitoring. The critical monitoring algorithm is verified in two cases: tool wear monitoring and chatter detection. The results show that the method proposed can accurately evaluate the percentages of the residual useful life of the tool and the chatter. Moreover, a new process monitoring system in small batch machining is developed by integrating the advanced algorithm. This study can provide a critical reference for intelligent machining monitoring and control in industry.