This study presents a digital twin of 5-axis milling processes for thin-walled parts to predict and prevent the occurrence of static deflection issues, surface location error due to forced vibration, and regenerative chatter. Driven by real-time machine signals or machining programs, the twin continuously simulates the milling process given an initial workpiece and any 5- axis toolpath. Thanks to the implementation of an automatic mesher and a finite element model generator, the stiffness and dynamics of the part are determined based on its current geometry. This enables the digital twin to predict and visualize in 3D the static deflection, forced vibration, and process stability, allowing optimization of the process and avoidance of these issues. Finally, the twin is validated on a 5-axis machining case of a steel blade, in which a surface location error caused by a resonance is diagnosed and eliminated.
Chatter vibrations in cutting are uncontrolled (self-excited) vibrations in a machine–tool–workpiece system, occurring without the involvement of external forces. They result in accelerated tool wear and reduced surface quality. One way to avoid self-excited vibrations is to optimize cutting parameters based on stabili...
J. Zielińska-Szwajka, K. Szwajka, T. Trzepieciński et al.· Forests· 0 citations
The tool-workpiece engagement dynamics in milling involve abrupt interaction forces that can degrade manufacturing performance. This paper presents a machine learning-based real-time digital twin, iTwin, for end-mill deformation estimation and chatter suppression. By integrating cutting force sensing, milling dynamics,...
Yi Huang, Feng Han, Jin-Gang Yi et al.· 2026 IEEE 22nd International...· 0 citations
A coupled finite element–finite difference framework was developed to simulate high-speed peripheral milling of A2024-T351 aluminum alloy, enabling the analysis of chip formation, thermal gradients, and dynamic instability. The finite element model was used to predict the thermo-mechanical response and chip formation,...
Rami Smari, Ltaief Lammari, Ali Rakrouk et al.· Sound & Vibration· 0 citations
A reconfigurable, flexible, and modular fixture system is proposed for the milling of irregular thin-walled parts, which are commonly encountered in aerospace applications and require high machining precision. Conventional universal fixtures often fail to provide adequate support for such components, particularly in te...
Gui-Hua Liu, Yu-Chao Wu, Shi-Neng Peng et al.· Journal of Manufacturing and...· 0 citations
In complex-surface milling, the cutter attitude changes from one tool-path segment to another, so the frequency response function (FRF) of the tool system near the cutting zone is not constant. This point is important in practice because the same spindle speed may lead to different behaviours as the local posture chang...
Chang-Gang Yan, Zhi-Yang Qi· Journal of Physics, Conferen...· 0 citations
Titanium alloy (Ti-6Al-4V) exhibits exceptional comprehensive properties, which have resulted in its widespread adoption across diverse industrial sectors. However, its poor machinability poses a significant bottleneck to achieving high-efficiency and high-precision manufacturing. To address the challenges inherent in...
