Digital Twins for Micro Machining

Abstract

The digital twin is a virtual mirror of the physical world throughout its life cycle. A cutting
process controlled by digital twins can be a modern solution for manufacturing. Continuous data
collection using virtual twin simulation and physical twin experimentation is related to modified
vibration micro drilling processes, improving the quality of operations. The main research question is
how to quickly create a virtual model, and the mechanism for deploying the connection between the
physical world production system and the virtual model it reflects. Over the last two decades, the
demands of drilling small holes (Ø 0.5 mm) at high rotational speed (80.0÷180.0 rpm) are increasing
due to the trend towards higher density circuits of computer parts and microelectronic packaging
products. Compared to various micro machining methods, the main advantages of mechanical micro
drilling are: less complicated equipment is necessary, the process is cheaper, the electrical properties of
the workpiece do not influence the process, and machining time can be controlled easily. Buckling
stiffness of micro drill bit is essential factor in order to secure the quality of micro drilling process,
most of micro drill bit failures happen because of buckling. The aim of this study is to investigate the
possibilities to increase micro drill stiffness by buckling it on a higher mode of the tool. This would
allow to use higher cutting parameters and to increase efficiency of the micro drilling process.