A PROJECT REPORT ON

HYBRID APPROACH FOR PREDICTIVE MAINTENANCE

USING DIGITAL TWIN

THESIS
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR
THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

SUBMITTED BY
SNEH SONAM 17070125113
SHERON SISODIYA 17070125108
MEHR BILLAWARIA 17070125067
UTKARSH NATH 17070125122

Under the Guidance of

PROF. PRIYA JADHAV

SYMBIOSIS INSTITUTE OF TECHNOLOGY

A CONSTITUENT OF SYMBIOSIS INTERNATIONAL (DEEMED UNIVERSITY)
Pune - 412115

YEAR- 2017-2021

i
 A PROJECT REPORT ON

HYBRID APPROACH FOR PREDICTIVE MAINTENANCE

USING DIGITAL TWIN

THESIS
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR
THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

SUBMITTED BY
SNEH SONAM 17070125113
SHERON SISODIYA 17070125108
MEHR BILLAWARIA 17070125067
UTKARSH NATH 17070125122

Under the Guidance of

PROF. PRIYA JADHAV

SYMBIOSIS INSTITUTE OF TECHNOLOGY

A CONSTITUENT OF SYMBIOSIS INTERNATIONAL (DEEMED UNIVERSITY)
Pune - 412115

YEAR- 2017-2021

ii
 CERTIFICATE

The thesis entitled “Hybrid approach for Predictive Maintenance using Digital Twin”
submitted to the Symbiosis Institute of Technology, Pune for the award of B. Tech in
Mechanical Engineering is based on my original work carried out under the guidance of Prof.
Priya Jadhav. The thesis has not been submitted elsewhere for award of any degree.

The material borrowed from other sources and incorporated in the thesis has been duly
acknowledged and/or referenced.

I understand that I, myself could be held responsible and accountable for plagiarism, if any,
detected later on.

Date: 16 September 2020

Signature of the candidate

(Name of the candidate)

Research supervisor HOD Director

(Name of the supervisor) Name Name

iii
 CONTENTS

LIST OF FIGURES iv
LIST OF TABLES iv
LIST OF ABBREVIATION iv
ABSTRACT iv
CHAPTER I: INTRODUCTION 1
CHAPTER II: LITERATURE REVIEW 3
2.1 LITERATURE GAP 6
CHAPTER III: OBJECTIVE 8
CHAPTER IV: METHODOLOGY 9
4.1 DESIGN OF DTMT DESCRIPTIVE MODEL 9

4.2 MULTI-DOMAIN MODEL IMPLEMENTATION 9

4.3 CUTTING TOOL DATA-DRIVEN MODEL REALISATION 9

4.4 MODELLING AND SIMULATION METHOD OF CNCMT 10

CHAPTER V: RESOURCES AND LIMITATIONS 15

BIBLIOGRAPHY 17
APPENDICES

LIST OF FIGURES/TABLES

iv
Fig. 1 CAD model of Milling Machine

Fig. 2 SIMULINK block representation of CAD model

Fig. 3 Block representation of different parts of the CAD model

Fig.4 SIMULINK one mass model for Y-axis feed drive model

Fig.5 SIMULINK one mass model for X-axis feed drive model

Fig.6 Cutting force model for X-axis and Y-axis feed drive model

Table 1 Parameters used in creating the SIMULINK model of Feed Drive System

LIST OF ABBREVIATIONS

CNCMT Computer Numerical Control Machine Tool

v
 DT Digital Twin
GRU Gated Recurrent Unit
ARMA Auto Regressive Moving Average
PHM Prognostics and Health Monitoring
CPS Cyber Physical System
ANFIS Adaptive Neuro Fuzzy Inference System
IMT Intelligent Machine Tool

ABSTRACT
CNCMT is a typical manufacturing equipment and is therefore known as the mother machine of
industry. Any fault in CNCMT might cause loss of precision and will affect production if
troubleshooting is not done from time to time. Therefore, there is a big significance of reliability
of CNCMT. Predictive maintenance is an effective method to avoid faults, error and casualties.

vi
Due to less consideration of the status variety and consistency of CNCMT in its life cycle,
current methods cannot achieve accurate, timely and intelligent results. For reliable and accurate
predictive maintenance of CNCMT, a hybrid approach is studied which is driven by DT. This
approach is DT model-based and data-driven hybrid. With the proposed framework, a hybrid
predictive maintenance algorithm based on DT model and DT data is researched.

For the virtual modelling of the system the Matlab SIMULINK software was used. The influence
of changing and optimizing several feed drive parameters such as position loop gain Kv,
proportional gain Kp of the velocity controller, integral gain of velocity controller Tn, electrical
drive time constant Te, total moving mass m, sampling period Ts, etc., on the positioning
accuracy and the dynamic stiffness was simulated, tested and validated. The cutting force model
was also considered to predict the tracking errors in the milling process.

At last, the tracking errors predicted using the proposed model are compared to those predicted
using the traditional model without consideration of the transmission path.

vii
 INTRODUCTION

Mass production has now evolved into customized production with the steady increase of smart
and automated manufacturing. As technology keeps developing, manufacturing develops with it.
What we now know as digital networked manufacturing was earlier digital manufacturing and
will soon become the latest intelligent manufacturing by becoming more digitized, intelligent
and automated.

These changes have created challenges for fault detection and predictions which are considered
for new products, increasing the accuracy of prediction and product customization. Signal
analysis is typically the method used for the detection of fault and this is mostly dependent on
the operator’s experience and inspections. Usually statistical data are used to make prediction
using the runtime data. Digital twin is what we will use for fault prediction inorder to optimize
the dependability, accessibility and safety of the machine.

CNC machine tool’s performance and reliability is determined by the quality of products it will
process during its working. The non-linearity in the process along with the noise is what causes
degradation in the performance of the Computer Numerical Control machine tool. As a result, an
error occurs in the prognosis. Decrease in performance is a time-varying process. These previous
methods of error deduction do not take into account the regularity and uniformity of the
apparatus during the cycle of its life. This in turn causes the outcome of the predictive
maintenance to be flawed, inconsistent and imprecise. We can create a data model based on the
information that indicates the strength and longevity of the apparatus in order to use it to
diagnose and predict the life of equipment.

There are numerous defects and reasons that cause hindrance and result in getting an inaccurate
output. Noise and the lack of comprehension of the various attributes of the machine are included
in these. Inorder to execute the hybrid predictive approach and overcome the defects, many
scholars proposed the idea of a Digital Twin. Hybrid predictive maintenance can be implemented
effectively with the help of DT concept CPS are enabled by Digital Twins.

1
Digital Twin allows the CPS method to be executed. It uses laws of physics and thus results in
having an extremely accurate digital model. This model can then cache historical data used while
running inorder to be used further. It can also procure and sense data in real time one the
equipment is utilized.

2
LITERATURE REVIEW
Production time studies in smaller businesses show that each operation's machining and 
assembly activities constitute just 5% of the entire length of the operation. The other 95 percent 
of the operational time reflects the location of physical resources during setup periods during the 
preliminary operations or the waiting before the next operations. Most of the working time is 
often spent excessively on transport and storage, etc. Nyhuis P et al., 2009 [1].

A paradigm shift from 'real' to 'virtual' output has resulted in an increase in research interest in 
the field since the early 1990s. Simulating some of the operations of a physical production 
system has become possible with the help of computers. The main goal is to understand and 
simulate the behavior of a specific production system on a machine prior to physical 
manufacturing, thus minimizing the quantity of tests and experiments on the shop floor.
Less material is lost by the use of a computer device and interruptions can be avoided in the oper
ation of an actual machine on the shop floor Radharamanan R, 2002 [2].

The method developed for the success of virtual output was focused on literature findings and
practical experience. The approach is referred to as PoVEIR (Production in Virtual Environment 
Integrating Resources) and is explicitly designed to optimize production processes in smaller co
mpanies characterized by special small-scale and variable volumes of production.
So far, different modelling and simulation techniques have been introduced in the field of CNC 
machining. They are important for the improvement and cost reduction of manufacturing.
Onosato M (1993), Mwinuka T.E (2015), Debevec M (2014), Čuš, F (2015), Hrelja M (2014)
and Todorovic P (2014) [3,4, 5, 6, 7, 8].

The objective of modern manufacturing technologies is to produce the first part correctly and in 
the most costeffective way in the shortest period of time. The construction and testing of physical
prototypes are major bottlenecks for the successful and economically advantageous production 
of modern machine tools, as the product complexities increase and the competitive product life 
cycle times are reduced Weck, M et al., 2003 [9].

The creation of modern software tools for the simulation of product properties has been greatly 
enhanced in recent years, initiated primarily by the automotive and aircraft industries Weck M.
et al., 2003 [10].

Before the first physical prototype is constructed, advanced software and hardware systems
allow design engineers to test and optimize critical product characteristics with virtual prototypes
For the various design phases of a machine tool, a large range of software tools are available
Weule, H et al., 2003 [11].

Presently, the machine tool builders can no longer afford the time consuming and

costintensive manufacturing and testing of physical prototypes to find weak points and then 
optimise the design. Instead, modern machine tool design processes employ "virtual prototyping"
technology to reduce the cost and time of hardware testing and iterative physical prototype 

3
improvements. A computer simulation model of a physical product that can be interpreted and
analysed like a real machine is the virtual prototype of a machine tool. During the design process
, iterative change of a simulated model of the machine tool and exercise design variationsbefore t
he performance criteria are met reduces the entire product development time and costs significan
tly Altintas Y et al., 2005 [12].

CNC Machine Tool

As the industry's mother computer, the CNC machine tool (CNCMT) is one type of significant
production equipment . The achievement CNCMT's consistency and reliability determines the
quality of the goods it has being stored. CNCMT, however can unpredictably incur defects,
which low accuracy, stagnation of output or even significant loss and loss can be caused. 
Casualties if there is no prompt troubleshooting. Predictive maintenance is therefore required to
prevent faults and increase the reliability of faults with CNCMT T. Kjellberg et al., 2009 [13].

Traditionally, the form of reliability statistics is generally used for Predict based on the statistical 
features of historical characteristics Data on faults. However the approach of reliability statistics 
needs a lot of checks, Historical and detailed data, which is difficult to apply for complex andco
mplex Large-scale, costly facilities, such as aircraft, machine tools, nuclear devices electric
power stations, etc. Another is the physical model-based method which by defining the digital
device model, physical failure model and fatigue life model, conducts fault predictions N. Cauch
et al., 2017 [14]. It is heavily dependent on the expertise and knowledge of experts to create an
effective mathematical model for complex electromechanical systems. The variety of status and
quality of equipment during its life cycle are not taken into account by these two types of
approaches, resulting in unreliable, untimely and unintelligent prediction outcomes.

As new generation technologies such as sensing, monitoring, simulation, big data and artificial
intelligence (AI) are being developed, Many smart methods have been applied to manufacturing,
which Providing an efficient means of predictive maintenance powered by the Data from
manufacturing J. Wang et al., 2019 [15]. Based on the monitoring of historical circumstances,
Equipment info, characteristics reflecting the health status of equipment The data-driven model
for prediction and prediction can be extracted to construct the Diagnosis of machinery. The
performance of different algorithms varies according to the characteristics of the target system
for the data-driven process. As well as its information and inaccuracy occurs because of the lack
of understanding The physical features, noise and uncertainty of equipment Duan L et al., 2016
[16].

Many scholars have suggested the hybrid predictive maintenance approach to resolve the defects
of the above-mentioned approaches H. Hanach (2019) and L. Liao (2016) [17,18]. By The
benefits of each process are augmented by the creation of a fusion technique. To understand the

4
hybrid predictive maintenance strategy, however it is important to develop precise mathematical
and physical Models, obtain accurate running data in real time, and render useful data.

Current Predictive Maintenance Methods

Currently three methodsare mainly used for predictive maintenance of complex equipment,
namely the method of reliability statistics, the method based on physical models and the method
based on data, as shown in Fig. 1. Each method has its own features and fields that apply Mobley
R K, 2002[19].

Fig. Current predictive maintenance methods.

(1) Reliability statistics method: Statistical features of historical fault data are used for fault
prediction in the reliability statistics method, as shown in Fig. (a), in which less detailed
information is required and no specific data or mathematical model is required Shimada J (2016)
and C. Li (2012) [20, 21]. A series of different probability density functions contain the

5
information required for prediction. Weibull distribution, Bayesian method, and fuzzy logic, etc.,
include fault prediction methods based on reliability statistics.

For commercial products in large batches, these methods are mostly used. It is not suitable for
complex and costly equipment or systems containing millions of parts and components, such as
spacecraft, aircraft and CNCMTs. Moreover this technique does not take into account the
complex operating environment, equipment performance degradation, and so on, resulting in low
prediction accuracy and confidence levels.

(2) Physical model-based method: The physical mathematical model reflecting the
performance degradation of the system is established according to the internal working
mechanism of the target system in the physical model-based method Ortiz J et al., 2016[22], as
shown in Fig. (b) from Y. Lei (2016) and B. Iung (2008) [23,24]. The essence of the physical
object can be clearly described by a mathematical model through which the degradation trend of
the object can be predicted to achieve the precise results of the fault prediction.

Although the physical model-based technique can reveal the system's fault logic without
collecting a lot of data, it needs expert support to design and develop the model. Most of the
machinery is typically complex mechanical and electrical systems, the corresponding
degradation models of which are difficult to accurately determine due to the lack of degradation
mechanism.

(3) Data-driven method: Data can be collected from running devices in the data-driven
predictive maintenance method, and no precise fault evolution model or performance
degradation process is required M. Baptista (2018), Daily J, Canizo M (2017) and J. Wang
(2019) [25 - 27]. For the analysis of big data, autoregressive model, artificial neural network
support vector machine, correlation vector machine, Gauss regression process etc are commonly
used J. Wang et al., 2019 [28],. As indicated in Fig. (c), features are extracted from historical
data and then converted into system knowledge. Via data collection and analysis, system
information on health status and deterioration that is concealed in data can be mined.

Many sensors are usually installed to collect data in order to obtain the operational status and
information of equipment, but some key components are unable to install sensors, resulting in
data acquisition and further data analysis difficulties J. Wang (2017) and J. Xie (2017) [29, 30].
What's more, in different systems, different algorithms have discrepant results. Therefore to find
the most appropriate algorithm and corresponding parameters, heavy work is required for the
algorithm experiments.

In summary, there are different flaws in the existing predictive maintenance approach based on a
single technique and do not satisfy the criteria of greater precision and reliability for fault
prediction. With the advent of new technologies, as shown in Fig., the hybrid approach (d) has
been a hotspot for research L. Liao (2016), J. Wang (2015) and Y. Liang (2020) [31 - 35]. In a

6
hybrid approach, it is possible to follow the benefits of each method, essentially eliminating the
disadvantages of each single method.

The Development of Digital Twin

With the evolution of production towards intelligent mode, automation, convergence, there has
been an increased concern about Digital Twin and its growth as a in Fig. illustrated 1. Initially,
the idea of "twin" was initially derived from the Apollo Project of NASA, when the aircraft was
A real physical system is a twin body Hochhalter J et al., 2014 [36]. Nowadays a twin body
models can help astronauts and personnel make decisions in the context of Situations of
emergency. Then the Digital Twin idea First of all, a product lifecycle is proposed for the
formation of The 2002 Management Center Rosen R et al., 2015 [37]. Enabling the Internet of
Things to help new intelligent services, the Digital Twin model connecting and interacting with a
physical object Wang, P and Zuehlke D., 2015 [38, 39]. These ones, these Capabilities allow
producers to recognize and drive new business models, including real-time simulation and fault
simulation prediction Tao F et al., 2014 [40]

Fig. 1. Evolution of Digital Twin technology

There are several companies visualizing and implementing real life in terms of Digital Twin
applications, such as General Electric, PTC, NASA, Siemens and so on.

Currently, several studies have been conducted on digital twins Rosen R(2015), W. Luo(2018),
Guo(2018), Zhang(2017), QiangLiu(2018) and Jiewu Leng(2018) [41-46]. From the above
research and studies, it can be found that a lot of work has been done in the development of
digital twin-based computer tools involving technologies such as big data processing, the

7
Internet of Things, cyber-physical systems and cloud computing. The benefits of the digital twin
in terms of diagnosis and prognosis of fault are that it is possible to process information from
diverse or different sources and to track the actual working conditions, and that the predictive
results may be put in the digital model to demonstrate the precision of the cutting quantity or to
better feed the tool system Jinjiang Wang et al.[47].

With the advancement of technology, the approaches to tool system fault prognosis are also
strengthened. There are several work on data-driven approaches to prognosis at the moment. A
new system for tracking the state of motor bearings and diagnosis of faults is used for
undersampling vibration signals Siliang Lu et al. [48]. The community method of data handling
(GMDH) suggests the method of predicting and detecting cutting tool failure in a process device
Uematsu T et al. [49]. Such methods of diagnosis and prognosis based on statistical processes
have been suggested El Wardany T, Lamiaa M, Kang J (2007) and Park S [50-53]. The above
model and methods are all about the model-based approach to prognosis.

There are some special benefits of current methods of fault prognosis. However there are some
drawbacks: 1) the system is always too stochastic to model for some, 2) the approach relies
heavily on expert expertise and requires a large number of rules, 3) the model lacks a scheme to
update the model with new test data.

Thus to help the study of fault diagnosis and prognosis, a Digital Twin reference model is hereby
investigated. Big data is used for sensor information interpretation and processing, and the
computer control machine accepts the digital signals and directs the physical devices by CPS to
the next steps. The model algorithm for fault prediction is given by deep learning. This
methodology is paired with a data-driven and model-based strategy. An effective virtual and real
model of interaction can be created, which can truly represent the type of movement and the
material structure of physical objects in the virtual world. In addition, the projected effects are
easy to visually show in three dimensions, which may allow operators to appreciate the outcomes
of the prognosis.

The Synthetic Nature of Digital Twin model

In essence, Digital Twin is a special living physical device model with support for enabling
technologies such as multi-physics simulation, machine learning, AR/VR and cloud service, etc.
It allows for continuous adaptation to environmental or organizational changes and produces the
best business performance. It offers tremendous potential for improving operations and
maintenance, as well as further speeding up the pace of the process generated by the new
product.

Just in Fig. , we present a new ontology focused on digital twin technology knowledge from
current literature and analysis, showing a digital twin model tool system in terms of six

8
technology features, four service implementations, four advantages and three enabling factors
used to drive the development of the digital twin model tool system.

Fig. . Characteristics, service, advantage and enabling factors defining tool system digital twin
model.

Various aspects of technology (cyber-physical structures, IoT/IoS, AI, unique identifier),

resource utilization (energy efficiency) and processes (cloud development, multiple data
communication and physical-virtual interaction) constitute the characteristics of the digital twin
model. As a new generation of systems with computer and physical capabilities, cyber-physical
systems will create a strong bridge between humans and the world of digital information Baheti
R et al., 2011[54]. The Internet of Things (IoT/IoS) uses various sensors (such as radio
frequency recognition, infrared induction and global positioning, etc to process vast volumes of
data of different types in order to realize the functions of risk identification, fault location and
safety management Kelly S et al. [55]. From a security point of view, there are several resources
(Process control/Process monitoring, Fault diagnosis and prognosis, Alarm management, Shorten
MTBF) in the latest proposed digital twin model of tool system.

9
Digital Twin achieves human-machine interaction and is able to communicate in real time with
the world and physical entities. It has a unique identifier that is related only to the device of the
tool. The technology is incorporated in the digital twin model with AI (ontology, machine
learning and deep learning, etc.). Due to the feedback mechanism of the digital twin model, it
can effectively help to correct errors in the design process of the tool system. Digital Twin
allows the model, motion, and fault visibility of the tool system, and can reliably determine
whether the feed system or the failure of the tool.

In Fig., the enabling factors 2 are defined as education, knowledge and rules of conduct.
Innovative education provides people with higher criteria for smart manufacturing and opens up
a wider view. More specific technology for data processing needs to accommodate a large
volume of data processing. When it is designed, the code of behavior guarantees the consistency
and continuity of the digital twin model.

Feed Drives
Feed drives are the most significant components of each machine tool. The feed drives are very 
complex electro-mechanical systems for CNC machine tools. In particular good control
dynamics, position precision, load stiffness, acceleration capability and process velocity must be 
displayed Gross H (2006) and Pandilov Z (2014) [56, 57].

The numerous errors of each feed drive axis for machine tools should be investigated Ramesh R
et al., 2005 [58] to achieve high precision machining. A machine tool consists of servo motors,
spindles, structures, etc., and a complex interaction of many factors such as servo dynamics,
friction, structural vibration, thermal effects, and cutting dynamics is its dynamic response
Ramesh R (2000) and Muhammad BB [59, 60].

It is possible to represent the simplified linear dynamics of a typical feed drive, as shown in Fig.
Here, u '(V) is the control signal applied to the current amplifier input, denoted by the Ka (A/V)
gain. The amplifier induces the current i(A) in the armature of the motor, resulting in the Tm
(Nm) motor torque, which is linearly proportional to I with the Kt (Nm/A) motor torque
constant. The motor shaft is also subjected to a disturbance torque Td (Nm) in addition to the
torque generated by the current running through the armature, which includes the effect of
friction in the guideways, ball screws and bearings, as well as the cutting forces Y. Altintas et al.,
2005 [61].

10
 Fig. Linear dynamics of a feed drive

Many studies have examined methods to minimize static or dynamic errors, such as suppression
of structural vibration, enhancement of servo rigidity, compensation for friction or backlash,
avoidance of chatter, and compensation for thermal errors. The dynamics of the configuration of
a machine tool can be calculated using the process of receptance synthesis Zhang GP et al., 2003
[62]. To simulate the interaction between the structure and cutting dynamics of a machine tool an
effective position-dependent multibody dynamic model of a machine tool was developed Law M
et al., 2013 [63]. To enhance the servo response a feedforward controller was applied Wu J et al.,
2017 [64]. To predict the tracking error, a robust tracking servo device with the feedforward
controller using coprime factorization and disturbance observer was implemented Ohishi K et al.,
2006 [65]. The servo output of the system table during pre-sliding to sliding can be strongly
influenced by friction and backlash. Different friction and backlash models were proposed to
improve its efficiency and the related compensation methods were investigated Erkorkmaz K
(2001), Chen Y (2002) , Olsson H (1998) and Nguyen BD (2007) [66-69]. Therefore the
aforementioned literature shows that the relations between servo dynamics and the method of
cutting have rarely been addressed.

Integrated models of servo feed drive and cutting force

Milling is a cutting process that uses a milling cutter to remove material from a workpiece. The
electromechanical architecture of a CNC machine tool includes a CNC controller, a servo drive
system, a mechanical system, and so on, as presented in Fig. The CNC interprets G-codes, plans
for acceleration and deceleration, and then sends the servo position commands and spindle speed
commands to the servo and spindle drive systems, respectively, at different sampling times. To
provide better positioning accuracy of the machine table, the servo drive system usually adopts a
full-closed loop position control by using a linear scale to feedback the current position of the
table. In the current section, the end-milling cutting force model and the servo drive model are

11
presented separately and then combined as an integrated system model Chen-Jung L et al.,
(2019)[70]

Fig. The architecture of an end-milling process and a servo feed drive for a CNC machine tool system

12
LITERATURE GAP

The fact that the literature mainly comprises conceptual studies rather than studies of particular
case is indicative of how DT is still in its very early phases of development. Although lower
level studies of assimilation like DS and DM do exist. As demonstrated, production planning and
control is one of our key focuses based on the latest research about DT in production and
manufacturing due to the fact that it is a chief data sink in a system of production that binds each
thing. Therefore, a lot of times simulations are used to make the most of the models at their best
because it has a middle level time horizon. Although, areas that have higher frequencies of time
can also use DT.

An example of this is the utilization of maintenance that is based on the control of the process
and also its conditions without the usage of simulations that are time intense; Rather, information
and data driven methods are used. To be able to understand the benefits that can be attained with
the help of DT, we need to research various case studies in different environments of the
industry.

Most of the researchers have excluded the cutting force model in the design. We have included it
in our design because the main performance is the machining quality of the workpiece.

13
OBJECTIVE

In the manufacturing industry, the computer numerical control machine tool (CNCMT) is
considered to be the one of the most important machines of the industry. The machining process
we selected is cutting and the component we chose is the cutting tool due the major role it plays
in the process. The surface finish, and accuracy of dimensioning are some of the few important
things that make this tool very important. The key objectives of our paper are as follows:

1.) To find the reliability of CNCMT inorder to troubleshoot the problems in the tool to avoid
negative effects on production like loss of precision, etc.

2.) To make a virtual model of CNC machine feed drive system using MATLAB Simulink, and
then simulate the results.

3.) To make the cutting force model to find the tracking error in the milling process.

4.) To compare the tracking errors predicted using the proposed model and the traditional
model.

14
 METHODOLOGY (WORK PROGRESS TILL DATE)

Design of DTMT descriptive model

CNCMT is an intricate mechatronic system that contains many objects with many properties.
We closely assimilate various stages of the lifecycle of a machine tool with a multi-domain
consolidated model so as to satisfy the need of DTMT. In order to recognize the self-adaptation,
self-prediction and self-evaluation of DTMT, we consider the general comprehensive
performance of the model along with how different parts are coupled. The strategies of design
and simulation of multi-domain machines include a software program interface method.

Multi-domain model implementation

The first step in the study is the creation of a virtual 3D CAD model of CNC portal milling
machine with a direct lead screw feed drive for all three axes. While building the model, we need
to take into account various areas and domains of physics like thermodynamics, hydraulics,
mechanics, electronics, etc., SOLIDWORKS, MATLAB, Simulink are all software that support
multi-faceted modelling. So, with the aid of these software we can create models of objects like
the cutting tool, feed drive, form subsystems and then integrate these into a consolidated multi-
domain system.

Cutting tool data- driven model realization

The records accumulated from sensor-acceleration, reducing pressure (cutting force) and AE
statistics. The raw data tends to consist of trend items because of drift in sensors from variation
in temperature. Inorder to provide better accuracy in the positioning of the machine table, the
feed drive model consists of a full-closed loop position control by using a linear scale to

15
feedback the current position of the table. For the cutting force model, we assume that the end-
milling cutter and the workpiece are rigid and that the cutting force is proportional to the cross-
sectional area of the chip. Apart from this, the burrs in the sign waveform end up including noise
signs like random interference signal, power frequency sign and periodic interference due to the
superimposition of the noise sign with the raw facts that are sampled. Smoothing of raw
information is done for the purpose of reduction of the effect of the interference signals and the
improvement of the vibration curve smoothness.

Modelling and simulation method of CNCMT

1. The first step is the creation of a virtual 3D CAD model of one CNC portal milling machine
with a direct lead screw feed drive for all three axes.

Figure 1. CAD model of Milling Machine

2. On completion of the virtual model in SOLIDWORKS, we export the solid model into
Simulink using
Simscape Multibody.

16
 Figure 2. SIMULINK block representation of CAD model

3. Different parts of the solid model are imported into Simulink as blocks are connected to each
other. The blocks offer a very detailed information about the solid part.

Figure 3. Block representation of different parts of the CAD model

4. The next step in modelling is to create a Feed Drive System for X, Y and Z axis. All the three
axis require a separate feed drive system. We create a SIMULINK one mass model for all the

17
axis to check the influence of changing several parameters related to the drive system and the
compliance of the drive system in the frequency domain.

Parameters Variables Unit X axis Y axis

Position loop gain Kv 1/s 80 80

Sampling period Ts s 0.002 0.002

Time constant of the Te s 0.007 0.007

current loop

Proportional gain of the Kp As/rad 0.017 0.017

velocity controller

Integral time of the velocity Tn s 0.0028 0.0028

controller

Torque constant of the Km Nm/A 1.63 1.63

rotary motor

Constant for the Kg rad/m 1256 1256

transformation of linear to
rotary movement

Specific cutting force Kc N/mm2 1760 1760

18
Load inertia J kg m−2 0.019606 0.00196644

Velocity-loop proportional Kvp A/rad s−1 4.4375 4.4375

gain

Velocity-loop integral gain Kvi A/rad 495 495

Mass of the moving m Kg 60 60

elements

Number of teeth N Teeth 4 4

Spindle speed n rev/min 600 600

Servo gain Kn mm/ (V.s) 1 1

Exponent of the specific M 0.7 0.7

Specific actual cutting force Ke N/mm2 2 2

Axial cutting depth ap mm 2 2

Table 1. Parameters used in creating the SIMULINK model of Feed Drive System

19
 Figure 4. SIMULINK one mass model for Y-axis feed drive model

Figure 5. SIMULINK one mass model for X-axis feed drive model

Figure 6. Cutting force model for X-axis and Y-axis feed drive model

CNCMT is an intricate mechatronic system that contains many objects with many properties. We
closely assimilate various stages of the lifecycle of a machine tool with a multi-domain
consolidated model so as to satisfy the need of DTMT. In order to recognize the self-adaptation,
self-prediction and self-evaluation of DTMT, we consider the general comprehensive

20
performance of the model along with how different parts are coupled. The strategies of design
and simulation of multi-domain machines include a software program interface method.

RESOURCES AND LIMITATIONS

Correct and accurate simulation, self-adaptation, self-prognosis, self-evaluation and self-sensing

skills are skills that an intelligent CNCMT instrument ought to have, since it is a key instrument
to intelligent manufacturing. DTMT algorithm model is required to support the mentioned
features. DTMT is a real-time digital duplicate of CNCMT. The DTMT algorithmic model
provides some intelligent facilities and solutions navigated by running data on the basis of the
descriptive model of DTMT and the data from the mapping model.

ANSYS, MATLAB/ Simulink are examples of commercial software interfaces used in

interdisciplinary fields corresponding to a modelling method called software interface. The
software is quite mature because of the build-up of relevant skilled information, however
developmental difficulties were redoubled due to the compatibility of interfaces between
completely dissimilar computer coding programs.

21
CONCLUSION
Our paper proposes a method of maintenance where a DT drives a hybrid predictive maintenance
method for a Computer Numerical Control Machine Tool (CNCMT). Our paper uses an
approach to create a hybrid algorithm using software such as MATLAB and SIMULINK for
fault detection and maintenance.

In the given method, a multi-domain DT model is created using physical, electrical, hydraulic
and thermodynamic information to reflect the working conditions in their actual form. After this,
we use the different values and amalgamate them using our algorithm in order to give us results
that are more accurate than existing methods or methods that use a single strategy for prediction.
The experimental results illustrate that the tracking errors predicted using the proposed model are
more accurate than those predicted using the traditional model without consideration of the
transmission path.

BIBLIOGRAPHY

1. Nyhuis, P., & Wiendahl, H. P. (2008). Fundamentals of production logistics:

theory, tools and applications. Springer Science & Business Media.
2. Radharamanan, R. (2002). Virtual manufacturing: an emerging technology. age, 7,
1.
3. Onosato, M., & Iwata, K. (1993). Development of a virtual manufacturing
system by integrating product models and factory models. CIRP annals, 42(1),
475-478.
4. Mwinuka, T. E., & Mgwatu, M. I. (2015). Tool selection for rough and finish
CNC milling operations based on tool-path generation and machining
optimisation. Advances in Production Engineering & Management, 10(1).
5. Debevec, M., Simic, M., & Herakovic, N. (2014). Virtual factory as an advanced
approach for production process optimization. International journal of simulation
modelling, 13(1), 66-78.

22
6. Cus, F., & Zuperl, U. (2015). Surface roughness control simulation of turning
processes/Simulator sistema vodenja hrapavosti povrsine pri procesu
struzenja. Strojniski vestnik-Journal of Mechanical Engineering, 61(4), 245-255.
7. Hrelja, M., Klancnik, S., Irgolic, T., Paulic, M., Jurkovic, Z., Balic, J., &
Brezocnik, M. (2014). Particle swarm optimization approach for modelling a
turning process. Advances in Production Engineering & Management, 9(1), 21.
8. Todorović, P., Vukelic, D., Tadić, B., Veljkovic, D., Budak, I., Macuzić, I., &
Lalic, B. (2014). Modelling of dynamic compliance of fixture/workpiece
interface. International Journal of Simulation Modelling.
9. Weck, M., Queins, M., & Witt, S. (2003). Effektive Entwicklung von
Werkzeugmaschinen. VDI-Z, 145(10), 32-36.
10. Altintas, Y., Brecher, C., Weck, M., & Witt, S. (2005). Virtual machine
tool. CIRP annals, 54(2), 115-138.
11. Weule, H., Fleischer, J., Neithardt, W., Emmrich, D., & Just, D. (2003, June).
Structural Optimization of Machine Tools including the static and dynamic
Workspace Behavior. In The 36th cirp-international seminar on manufacturing
systems (Vol. 12, pp. 56-60).
12. Brecher, C., Esser, M., & Witt, S. (2009). Interaction of manufacturing process
and machine tool. CIRP annals, 58(2), 588-607.

13. Kjellberg, T., von Euler-Chelpin, A., Hedlind, M., Lundgren, M., Sivard, G., &
Chen, D. (2009). The machine tool model—A core part of the digital
factory. CIRP annals, 58(1), 425-428.
14. Li, C. J., Tseng, H. C., Tsai, M. S., & Cheng, C. C. (2020). Novel servo-feed-drive
model considering cutting force and structural effects in milling to predict servo
dynamic behaviors. The International Journal of Advanced Manufacturing
Technology, 106(3), 1441-1451.
15. Wang, J., Yan, J., Li, C., Gao, R. X., & Zhao, R. (2019). Deep heterogeneous
GRU model for predictive analytics in smart manufacturing: application to tool
wear prediction. Computers in Industry, 111, 1-14.
16. Duan, L., Xie, M., Bai, T., & Wang, J. (2016, June). Support vector data
description for machinery multi-fault classification with unbalanced datasets.
In 2016 IEEE International Conference on Prognostics and Health Management
(ICPHM) (pp. 1-6). IEEE.
17. Hanachi, H., Yu, W., Kim, I. Y., Liu, J., & Mechefske, C. K. (2019). Hybrid data-
driven physics-based model fusion framework for tool wear prediction. The
International Journal of Advanced Manufacturing Technology, 101(9-12), 2861-
2872.
18. Liao, L., & Köttig, F. (2016). A hybrid framework combining data-driven and
model-based methods for system remaining useful life prediction. Applied Soft
Computing, 44, 191-199.
19. Mobley, R. K. (2002). An introduction to predictive maintenance. Elsevier.
20. Shimada, J., & Sakajo, S. (2016, July). A statistical approach to reduce failure
facilities based on predictive maintenance. In 2016 International Joint Conference
on Neural Networks (IJCNN) (pp. 5156-5160). IEEE.

23
21. Li, C., Zhang, Y., & Xu, M. (2012). Reliability-based maintenance optimization
under imperfect predictive maintenance. Chinese Journal of Mechanical
Engineering, 25(1), 160-165.
22. Ortiz, J., & Carrasco, R. A. (2016, July). Model-based fault detection and
diagnosis in ALMA subsystems. In Observatory Operations: Strategies,
Processes, and Systems VI (Vol. 9910, p. 99102S). International Society for
Optics and Photonics.
23. Lei, Y., Li, N., Gontarz, S., Lin, J., Radkowski, S., & Dybala, J. (2016). A model-
based method for remaining useful life prediction of machinery. IEEE
Transactions on Reliability, 65(3), 1314-1326.
24. Iung, B., Monnin, M., Voisin, A., Cocheteux, P., & Levrat, E. (2008). Degradation
state model-based prognosis for proactively maintaining product
performance. CIRP annals, 57(1), 49-52.
25. Baptista, M., Sankararaman, S., de Medeiros, I. P., Nascimento Jr, C., Prendinger,
H., & Henriques, E. M. (2018). Forecasting fault events for predictive
maintenance using data-driven techniques and ARMA modeling. Computers &
Industrial Engineering, 115, 41-53.
26. Daily, J., & Peterson, J. (2017). Predictive maintenance: How big data analysis
can improve maintenance. In Supply Chain Integration Challenges in Commercial
Aerospace (pp. 267-278). Springer, Cham.
27. Canizo, M., Onieva, E., Conde, A., Charramendieta, S., & Trujillo, S. (2017,
June). Real-time predictive maintenance for wind turbines using Big Data
frameworks. In 2017 IEEE International Conference on Prognostics and Health
Management (ICPHM) (pp. 70-77). IEEE.
28. Wang, J., Fu, P., Zhang, L., Gao, R. X., & Zhao, R. (2019). Multilevel
information fusion for induction motor fault diagnosis. IEEE/ASME Transactions
on Mechatronics, 24(5), 2139-2150.
30. Wang, J., Yan, J., Li, C., Gao, R. X., & Zhao, R. (2019). Deep heterogeneous
GRU model for predictive analytics in smart manufacturing: application to tool
wear prediction. Computers in Industry, 111, 1-14.
31. Wang, J., Zheng, Y., Wang, P., & Gao, R. X. (2017). A virtual sensing based
augmented particle filter for tool condition prognosis. Journal of Manufacturing
Processes, 28, 472-478.
32. J. Wang, J. Xie, R. Zhao, et al., Multisensory fusion based virtual tool wear sensing for
ubiquitous manufacturing, Robot. Comput. Integr. Manuf. 45 (2017) 47–58.
33. Liao, L., & Köttig, F. (2016). A hybrid framework combining data-driven and
model-based methods for system remaining useful life prediction. Applied Soft
Computing, 44, 191-199.
34. Wang, J., Wang, P., & Gao, R. X. (2015). Enhanced particle filter for tool wear
prediction. Journal of Manufacturing Systems, 36, 35-45.
35. Wang, J., Liang, Y., Zheng, Y., Gao, R. X., & Zhang, F. (2020). An integrated
fault diagnosis and prognosis approach for predictive maintenance of wind turbine
bearing with limited samples. Renewable Energy, 145, 642-650.
36. Hochhalter, J., Leser, W. P., Newman, J. A., Gupta, V. K., Yamakov, V., Cornell,
S. R., ... & Heber, G. (2014). Coupling Damage-Sensing Particles to the Digitial
Twin Concept.

24
37. Rosen, R., Von Wichert, G., Lo, G., & Bettenhausen, K. D. (2015). About the
importance of autonomy and digital twins for the future of manufacturing. IFAC-
PapersOnLine, 48(3), 567-572.
38. Wang, P., Gao, R. X., & Fan, Z. (2015). Cloud computing for cloud
manufacturing: benefits and limitations. Journal of Manufacturing Science and
Engineering, 137(4).
39. Zuehlke, D. (2010). SmartFactory—Towards a factory-of-things. Annual reviews
in control, 34(1), 129-138.
40. Tao, F., Cheng, Y., Da Xu, L., Zhang, L., & Li, B. H. (2014). CCIoT-CMfg: cloud
computing and internet of things-based cloud manufacturing service system. IEEE
transactions on industrial informatics, 10(2), 1435-1442.
41. Rosen, R., Von Wichert, G., Lo, G., & Bettenhausen, K. D. (2015). About the
importance of autonomy and digital twins for the future of manufacturing. IFAC-
PapersOnLine, 48(3), 567-572.
42. Luo, W., Hu, T., Zhu, W., & Tao, F. (2018, March). Digital twin modeling
method for CNC machine tool. In 2018 IEEE 15th International Conference on
Networking, Sensing and Control (ICNSC) (pp. 1-4). IEEE.
43. Guo, J., Zhao, N., Sun, L., & Zhang, S. (2019). Modular based flexible digital
twin for factory design. Journal of Ambient Intelligence and Humanized
Computing, 10(3), 1189-1200.
44. Zhang, H., Liu, Q., Chen, X., Zhang, D., & Leng, J. (2017). A digital twin-based
approach for designing and decoupling of hollow glass production line. IEEE
Access, 5, 26901-26911.
45. Liu, Q., Zhang, H., Leng, J., & Chen, X. (2019). Digital twin-driven rapid
individualised designing of automated flow-shop manufacturing
system. International Journal of Production Research, 57(12), 3903-3919.
46. Ruiz, E., Osmani, V., Sucar, L. E., & Mayora, O. (2019). Detecting dressing
failures using temporal–relational visual grammars. Journal of Ambient
Intelligence and Humanized Computing, 10(7), 2757-2770.
47. Wang, J., Ma, Y., Zhang, L., Gao, R. X., & Wu, D. (2018). Deep learning for
smart manufacturing: Methods and applications. Journal of Manufacturing
Systems, 48, 144-156.
48. Lu, S., Zhou, P., Wang, X., Liu, Y., Liu, F., & Zhao, J. (2018). Condition
monitoring and fault diagnosis of motor bearings using undersampled vibration
signals from a wireless sensor network. Journal of Sound and Vibration, 414, 81-
96.
49. Uematsu, T., & Mohri, N. (1986). Prediction and detection of cutting tool failure
by modified group method of data handling. International Journal of Machine
Tool Design and Research, 26(1), 69-80.
50. El Wardany, T. I., & Elbestawi, M. A. (1997). Prediction of tool failure rate in
turning hardened steels. The International Journal of Advanced Manufacturing
Technology, 13(1), 1-16.
51. Elshenawy, L. M., & Mahmoud, T. A. (2018). Fault diagnosis of time-varying
processes using modified reconstruction-based contributions. Journal of Process
Control, 70, 12-23.

25
52. Kang, J., Kang, N., Feng, C. J., & Hu, H. P. (2007, November). Research on tool
failure prediction and wear monitoring based hmm pattern recognition theory.
In 2007 International Conference on Wavelet Analysis and Pattern
Recognition (Vol. 3, pp. 1167-1172). IEEE.
53. Park, S., Kapoor, S. G., & DeVor, R. E. (2006). Microstructure-level model for
the prediction of tool failure in WC-Co cutting tool materials.
54. Sanislav, T., & Miclea, L. (2012). Cyber-physical systems-concept, challenges
and research areas. Journal of Control Engineering and Applied
Informatics, 14(2), 28-33.
55. Kelly, S. D. T., Suryadevara, N. K., & Mukhopadhyay, S. C. (2013). Towards the
implementation of IoT for environmental condition monitoring in homes. IEEE
sensors journal, 13(10), 3846-3853.
56. Pandilov, Z., Milecki, A., Nowak, A., Górski, F., Grajewski, D., Ciglar, D., ... &
Mulc, T. (2015). Virtual modelling and simulation of a CNC machine feed drive
system. Transactions of FAMENA, 39(4), 37-54.
57. Pandilov, Z., & Dukovski, V. (2014). Analytical Determination of the CNC
Machines High-Speed Feed Drives Position Loop Gain. In Applied Mechanics
and Materials (Vol. 555, pp. 505-510). Trans Tech Publications Ltd.
58. Ramesh, R., Mannan, M. A., & Poo, A. N. (2005). Tracking and contour error
control in CNC servo systems. International Journal of Machine Tools and
Manufacture, 45(3), 301-326.
59. Ruijun, L., Wenhua, Y., Zhang, H. H., & Qifan, Y. (2012). The thermal error
optimization models for CNC machine tools. The International Journal of
Advanced Manufacturing Technology, 63(9-12), 1167-1176.
60. Muhammad, B. B., Wan, M., Feng, J., & Zhang, W. H. (2017). Dynamic damping
of machining vibration: a review. The International Journal of Advanced
Manufacturing Technology, 89(9-12), 2935-2952.
61. Altintas, Y., & Ber, A. A. (2001). Manufacturing automation: metal cutting
mechanics, machine tool vibrations, and CNC design. Appl. Mech. Rev., 54(5),
B84-B84.
62. Zhang, G. P., Huang, Y. M., Shi, W. H., & Fu, W. P. (2003). Predicting dynamic
behaviours of a whole machine tool structure based on computer-aided
engineering. International Journal of Machine Tools and Manufacture, 43(7),
699-706.
63. Law, M., Altintas, Y., & Phani, A. S. (2013). Rapid evaluation and optimization
of machine tools with position-dependent stability. International Journal of
Machine Tools and Manufacture, 68, 81-90.
64. Wu, J., Han, Y., Xiong, Z., & Ding, H. (2017). Servo performance improvement
through iterative tuning feedforward controller with disturbance
compensator. International Journal of Machine Tools and Manufacture, 117, 1-
10.
65. Ohishi, K., Miyazaki, T., Inomata, K., Yanagisawa, H., Koide, D., & Tokumaru,
H. (2006). Robust tracking servo system considering force disturbance for the
optical disk recording system. IEEE Transactions on Industrial electronics, 53(3),
838-847.

26
66. Erkorkmaz, K., & Altintas, Y. (2001). High speed CNC system design. Part II:
modeling and identification of feed drives. International Journal of Machine
Tools and Manufacture, 41(10), 1487-1509.
67. Chen, Y. Y., Huang, P. Y., & Yen, J. Y. (2002). Frequency-domain identification
algorithms for servo systems with friction. IEEE transactions on control systems
technology, 10(5), 654-665.
68. Olsson, H., Åström, K. J., De Wit, C. C., Gäfvert, M., & Lischinsky, P. (1998).
Friction models and friction compensation. Eur. J. Control, 4(3), 176-195.
69. Do, N. B., Ferri, A. A., & Bauchau, O. A. (2007). Efficient simulation of a
dynamic system with LuGre friction.
70. Li, C. J., Tseng, H. C., Tsai, M. S., & Cheng, C. C. (2020). Novel servo-feed-drive
model considering cutting force and structural effects in milling to predict servo
dynamic behaviors. The International Journal of Advanced Manufacturing
Technology, 106(3), 1441-1451.

27