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  4. Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills
 
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2025
Journal Article
Title

Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills

Abstract
Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and Machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network’s training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter’s profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model.
Author(s)
Jing, Yuan
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Gong, Guanchen
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Hänel, Albrecht  
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Ihlenfeldt, Steffen  
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Journal
Procedia CIRP  
Conference
Conference on Modeling of Machining Operations 2025  
Open Access
DOI
10.1016/j.procir.2025.02.062
Additional full text version
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Language
English
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Keyword(s)
  • Digital Twin

  • Hybrid Cutting Force Modeling

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