Twin-model based virtual manufacturing for machine tool-process simulation and control


Europe is the world’s largest manufacturer of machine tools but this position is threatened due to the emergence of Asian countries. However, Europe has world-class capabilities in the manufacture of high-value parts for such competitive sectors like aerospace & automotive and this has led to the creation of a high-technology, high-skill industry. European machine tool builders, part manufacturers and other agents have to work together to increase the competitiveness of European manufacturing industry.

Simulation tools are currently a key complement to European machine tool industry expertise but new integrated approaches are needed. The main objective of Twin-Control is the development of a simulation and control system that integrates the different aspects that affect machine tool and machining performance.

This holistic approach will allow a better estimation of machining performance than single featured simulation packages, including lifecycle concepts like energy consumption and end-life of components. This integrated concept will also enhance the necessary collaboration between machine tool builders and part manufacturers.

The specific industrial objectives are:

  • Getting machines that work as designed faster (10% reduction)
  • Getting production processes that work as planned faster (20% reduction)
  • To get a first-time-right part manufacturing (75%) • To increase production time trough model-based control (increase of 1-2%)
  • To reduce energy consumption (25-50%)
  • Improve machine reliability and increase machine up-time due to a proactive maintenance (2-4.5%)

All these will contribute to reduce machine tool life cycle costs (15 %) with a reduction of O&M costs in the range of 25%.

The project considers the validation and demonstrator in real production scenarios in aerospace and automotive industries. Added to this, 3 demonstrators will be set-up in three pilot lines for spreading results beyond the project end

More information
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Start date: 10-01-2015
End date: 30-09-2018
Total budget - Public funding: 5 600 241,00 Euro - 5 600 241,00 Euro
Call topic: Integrated design and management of production machinery and processes (FoF.NMPB.2015.14)

Project type - instrument - (1)