As Industry 4.0 has taken hold, the Digital Twin has gained popularity due to its obvious benefits. A Digital Twin is essentially a virtual representation of an element (like a machine, a workpiece or a process) that leads to consistent time savings and productivity gains.

The clear need for the Digital Twin

All manufacturing industries place special demands on production, and aerospace is no different. What’s more, aerospace quality requirements are sky-high, which means machining processes are complex and materials used are difficult to machine. And let’s not forget that final workpieces (such as turbine blades) are costly.

Add all of that up and the truth is apparent: production errors must be avoided at all costs. In such challenging manufacturing environments, the Digital Twin excels. This is why MÄGERLE MFP 30, MFP 50, MFP 51 and MFP 100 surface and profile grinding machines come equipped with a Digital Twin.

Benefit of Digital Twin #1:
reduced start-up time

Setting up a new workpiece can be time-consuming, especially if it’s a complex process. For aerospace turbine blades, 10 or more grinding operations are often performed in a single clamp.

A traditional approach for grinding these turbine blades involves programming, testing and optimizing each process step on the machine. But with the Digital Twin, all of this prep work is virtual. 

The entire surface and profile grinding process is simulated one-to-one on a computer, which optimizes the process. This added efficiency translates to up to 75% time savings, which can equate to multiple work days. In one such example, the use of a Digital Twin on a MÄGERLE machine slashed turbine blade setup from seven days all the way down to one.

Benefit of Digital Twin #2:
maximized machine production time

The vastly reduced setup phase instantly grants increased productivity since the grinding machine is freed up so much faster. In other words, the time savings granted by the Digital Twin instantly morph into money savings.

Benefit of Digital Twin #3:
provide programming and operation training in a virtual setting

Remember, the Digital Twin is an exact 1-to-1 representation of the machine’s control system. This means your programming and operating personnel can be trained on the Digital Twin instead of on the machine. Your machines’ production time stays up, and you also enjoy schedule and location flexibility for your training initiatives.

Benefit of Digital Twin #4:
lower risk of errors and damage

When errors are spotted virtually, they don’t have the chance to make a mess of things in reality. By simulating the grinding process with the Digital Twin, damage to your machines and workpieces are reduced. A significant advantage, particularly when working with complex and costly parts.

Benefit of Digital Twin #5:
a better ecological footprint

Doing your work in a virtual environment results in lower resource consumption on the machine itself. Time and money are saved, as well as energy and other resources required for production. 

In the market for a MÄGERLE? Ask for the Digital Twin.

Whether your shop is making turbine blades for aerospace or focusing on other surface & profile-friendly applications, don’t miss out on the strong time and money savings that come with a Digital Twin. Talk to UNITED GRINDING North America about the right machine for the parts you plan to make.