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A Generic Digital Twin Ecosystem for Computer Numerical Control Manufacturing Processes

Date

2025-07-17

Author

Pantelidakis, Minas

Abstract

This dissertation considers the design and implementation of a generic Digital Twin Ecosystem (DTE) for computer numerical control (CNC) manufacturing processes. The DTE architecture integrates real-time data acquisition, processing, and synchronization with the physical CNC assets, while accurately modeling their behavior under various operating conditions. The DTE utilizes two major components, namely the data Acquisition, Processing, and Distribution Component (APDC) and the Virtual Representation Component (VRC), which is developed using the Unity real-time development platform. The DTE is verified and validated through testing and experimentation in Additive and Subtractive Manufacturing case studies. Metrics consider response time, sequencing accuracy, seamless integration, job duration, virtual-to-physical mapping accuracy, and process-specific variables. The DTE is a unified platform for twinning and simulation. It achieves this by providing two modes of operation: the online mode allows for real-time process replication, ideal for monitoring and remote management, while the offline mode supports asynchronous G-code simulation, enabling what-if analysis and exploration of process variables. The two modes can be combined to enable predictive capabilities for autonomous process intervention. Industry professionals and academic scholars could use the DTE to make informed data-driven decisions, optimize machining processes, and ensure cost-effective and safe operations. This research contributes to the advancement of Digital Twin technology, particularly in CNC machining, fostering innovation in the manufacturing sector, and promoting the development of practical, cost-efficient, and reliable cyber-physical industrial systems, enhancing operational capabilities and productivity.