Using finite element analysis to develop a digital twin of a manufacturing bending operation
Eoin P. Hinchy, C. Carcagno, Noel P. O’Dowd, C.T. McCarthy
Abstract
In smart manufacturing, a digital twin is the virtual counterpart of a physical manufacturing system and can be considered as having three elements: machine, product and process. To demonstrate this concept, a physical manufacturing testbed was developed which bends metal into V-brackets alongside a digital twin counterpart consisting of the three elements. The process digital twin uses finite element modelling to predict product stress during the bending operation, and the residual stress and bend angle post-bending. The bend angles predicted by the process digital-twin were within 0.5° and 3° of the physical product for two different test scenarios.
Topics & Concepts
Residual stressFinite element methodBendingStructural engineeringEngineeringTestbedProcess (computing)Mechanical engineeringProduct (mathematics)Manufacturing processEngineering drawingComputer scienceMaterials scienceComposite materialGeometryAerospace engineeringOperating systemMathematicsDigital Transformation in IndustryAdditive Manufacturing and 3D Printing TechnologiesAdvanced Machining and Optimization Techniques