Supporting the Machining 4.0 Transformation

ESI has developed a unique High-Fidelity Prototype able to Predict the Machined Surface Quality Defects due to Workpiece & Tool Vibrations during Face Milling Operations. This will become the first brick of a more global solution based on the HydridTwin concept that will combine both Virtual & Digital Twin Machining Datas

by Gilles Croisonnier

Recent digitalization developments and the ever-increasing global competitiveness have made the utilization of virtual simulation tools and the collaboration between the physical world and the virtual work a key enabler for quality assurance as well as productivity.

To maintain an advantage, industries must rely on innovation and technological advancement as their main source of competitiveness – especially for parts that deform and vibrate significantly during machining. These phenomena pose major problems of non-conformity because often the topographical quality of the machined surfaces is insufficient and does not meet the needs demanded by the design offices or the customers.

Some toolmakers use numerical simulation, which gives them an advantage in specific problems, but they only provide a partial response to real needs. Today, the challenge is very real to develop innovative solutions based on more sophisticated physical models and this is the strategy of major corporations who desire to completely virtualize the manufacturing and design chain for high value-added parts. This is especially true in the automotive industry where OEMs are facing a tedious challenge with the machining of all the new metallic electric powertrain components.

Pr. Philippe Lorong 

Pr. Philippe Lorong is an expert in modelling dynamics for Machining System. He is currently heading the Dysco Research Group (Dynamic Structures Systems and Control) of the PIMM Lab.  Philippe is managing the Nessy2M development team that powers the ESI Machining Solution. Philippe has been teaching FE theory to student engineers and scientists in Mechanics at Ecole Nationale d'Arts et Metiers since 2008.


In this context, the Nessy2M research software (PIMM Laboratory), thanks to its transitional dynamic approach, fits in perfectly with this new market demand for predicting the wariness, roughness, and the deviations of shape on the machined surfaces in the presence of deformations or vibrations.

Through the IMPULSA and the SINUSOIDE Co-financed projects, ESI, with the support of seven industrial partners, has accelerated the industrialization of this innovative digital simulation technology. Thanks to this novel approach, delivery times can be drastically reduced and significant productivity gains can be realized.

Final Machined Surface Roughness for a Titanium Based Component. Courtesy of SAFRAN
Final Machined Surface Roughness for a Titanium Based Component. Courtesy of SAFRAN
Displacements and Vibrations Analysis during Machining. Courtesy of PCI SCEM
Displacements and Vibrations Analysis during Machining. Courtesy of PCI SCEM

Smart machining of monitored data, combined with model based-simulation, will become the next challenge in executing predicting maintenance. On-going EU Co-Financed IoTWIN project, IoTWIN, the project should help the push towards innovation. This project has been labeled by the three French Poles (ViaMECA/CIMES, ASTech, Nuclear Valley)

Project Partners
Project Financers

ESI looks forward to meeting you at INTERCUT 2020. Stop by the booth and experience live demonstrations of this technology!

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