Development of a Virtual Reality Model Using Digital Twin for Real-Time Data Analysis

Digital Twin (DT) machining technology enables real-time monitoring of machining operations, ensuring precision in the process. The virtual–real separation display method utilizes advanced DT systems, but it hinders the effective transmission of essential data to local technicians, thereby limiting the utilization of field processing supported by DT systems. Augmented Reality (AR) is employed to address the issue of monitoring the machining process, which is facilitated by a DT system. First, a dynamic multi-view for AR is created by incorporating data from various sources. Second, ongoing observation of the intermediate processing in AR promotes collaboration between the DT machining system and operators, particularly for complex products, preventing irreparable errors when the final product is nearly complete. The framework includes a module for data representation and detailed explanations are provided for the modules focused on data management and data organization. In a case study, the application of cutting tool wear prediction demonstrates the feasibility and the effectiveness of the proposed method for data construction. © 2023, The Author(s), under exclusive licence to Springer Nature Singapore Pte Ltd.