Industrial robots offer a good basis for machining from a conceptual point of view. However they are rarely utilized for machining applications in industry due to their low stiffness and the bad achievable work piece quality. Available solutions using position control of the tool require costly additional hardware and measurement equipment; force controlled solutions depend on low level controller access that is not commonly available for generic cell setups. This paper proposes a three-step approach to compensate for process force induced accuracy errors: (1) selection of appropriate milling strategies and cutting parameters, (2) an offline compensation of the force induced deviations and (3) a respective online compensation method. Experimental validation of the results has been performed for the first two steps.

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Twin-Control (http://twincontrol.eu/) is a novel concept for machine tool and machining process performance optimization. It combines several features in the field of ICTs in manufacturing towards a better performance of machine tools [1]. A holistic simulation model, a so-called Digital Twin [2] of the machine tool, integrating most important features of machine tools and machining process, is combined with monitoring and data management capabilities. Twin-Control will use a Digital Twin concept for the development of the simulation tool (Fig. 2.1). The Digital Twin is based on a combined application of the Cyber and Physical worlds, following the cyber-physical system (CPS) concept. The Cyber world consists in the computation, communication and control systems. The Physical world is composed by the natural and human-made systems governed by the laws of physics. A Digital Twin of the machine tool resulting from the combination of the different theoretical models that cover different aspects of the manufacturing process corresponds to the Cyber world, together with the cloud-based data management part,

Although process monitoring can facilitate to detect deviations from required part quality and safe process conditions, the analysis and postprocessing of the measured data are not embedded into the CAx workflow. Binding the measurement data together with material removal simulation creates a powerful tool for CAM programmers and process engineers. The user can analyze 3D visualization of the machining process more intuitively. A developed CAM integration simulates material removal considering the actual tool coordinates (measured during the process) and can depict the acquired and simulated cutting conditions (spindle torque, axes accelerations, etc.) with various color schemes on in-process stock simulation.