A digital twin study for immediate design / redesign of impellers and blades: Part 1: CAD modelling and tool path simulation

Arivazhagan Anbalagan, Bachu Shivakrishna, Kuthadi Sai Srikanth

Research output: Contribution to journalConference articlepeer-review

14 Citations (Scopus)


This paper presents a digital twining study conducted for an immediate design / redesign and manufacturing of on impellers & blades. It is by accomplished by developing (i) CAD automation methods, based on the standard modelling procedures and (ii) Manufacturing automation based on the 3/3 + 1/3 + 2/5 axis milling process. Initially, the CAD model of impeller / blade is created by utilizing the dimensional parameters obtained through standard design calculations / data. It is then parametrized and converted to an automated model through simple dimensional rules and geometric algorithms developed for the purpose. After this stage, the CAD model is analyzed for manufacturing automation where the process planning data comprising cutting tools, process parameters and setups are selected. Here, the tool paths are generated for 3/3 + 1/3 + 2/5 axis milling considering a CNC Vertical Machining Center (VMC) to digitally twin milling process. Both the CAD modelling and manufacturing process plans including tool path generation are captured through journaling and customized / improved using the Application Programmable Interface's (API's) to suit the present scope. In this paper, the first part on CAD modelling and manufacturing simulation methodologies are discussed through validating the digital twining concept in a virtual environment. The work is developed with the focus to help industries moving towards Industry 4.0 and requiring a constant design improvement in their products. It is by emphasizing the importance of digital twinning concept where a concurrent verification of design and manufacturing process can be achieved.

Original languageEnglish
Pages (from-to)8209-8217
Number of pages9
JournalMaterials Today: Proceedings
Issue numberPart 17
Early online date4 Apr 2021
Publication statusE-pub ahead of print - 4 Apr 2021
Externally publishedYes
Event3rd International Conference on Materials, Manufacturing and Modelling, ICMMM 2021 - Vellore, India
Duration: 19 Mar 202121 Mar 2021

Bibliographical note

Funding Information:
This article is an extended work (ongoing) from an earlier completed project “5 Axis STEP-NC (AP-238) Machining of Free Form / Irregular Contoured Surfaces” - SR/ FTP / ETA-62 / 2010. The author(s) gratefully acknowledges DST, Government of India, for funding the above project.

Publisher Copyright:
© 2021 Elsevier Ltd. All rights reserved.


  • Blades
  • CAD Automation
  • Digital Twin
  • Impellers
  • Machining
  • Process Planning
  • Simulation

ASJC Scopus subject areas

  • Materials Science(all)


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