Abstract: Considering the defects in mechanical processing,including unstable manufacturing,poor data timeliness and weak real-time monitoring visualization,in light of the principle of “combining the real with the virtual,controlling the real with the virtual”,a real-time monitoring method for milling cutter status was proposed based on digital twin technology,and the digital twins of co-existence and mutual control of physical space and virtual space were constructed.A structural model of milling cutter status monitoring system based on the digital twin five-dimensional model was built,and the composition of the five-layer system architecture was defined.Three key technologies to realize the twin system framework were elaborated respectively,that were the digital space construction of CNC machine tools,the transmission and management of multi-source heterogeneous data,and the digital twin-driven milling cutter condition monitoring.The milling of a thin-wall part was described to demonstrate the feasibility and effectiveness of the monitoring method,with a view to providing a new approach and idea for the comprehensive control of high-grade CNC machine tool processing.

Key words: digital twin, milling cutter status monitoring, five axis CNC machine tools, 3D visualization

摘要： 针对机械加工过程中面临的制造过程不稳定、数据时效性差、实时监控可视化效果弱等问题,本着“虚实结合、以虚控实”的总体思想,提出基于数字孪生的铣刀状态实时监控方法,构建了物理空间和虚拟空间共生互控的数字孪生体。首先,搭建了基于数字孪生五维模型的铣刀状态监控系统结构模型,明确了五层系统架构的组成部分;其次,分别阐述了实现孪生系统框架的3个关键技术,即数控机床的数字空间搭建、多源异构数据的传输及管理、数字孪生驱动的铣刀状态监测;最后,以某薄壁件铣削加工过程为应用案例,验证了该监控方法的可行性与有效性,并为全面管控高档数控机床加工过程提供了一种新途径和新思路。

关键词: 数字孪生, 铣刀状态监控, 五轴数控机床, 三维可视化