Enhancing metal-forming predictions with VR-infused digital twin models

Abstract

Abstract. This article presents a two-step method to enhance metal-forming predictions by integrating Virtual Reality (VR) into Digital Twin models, focusing on single-blow cold copper upsetting operations. The process begins with developing a real-time predictive surrogate model that considers actual process parameters, acting as a crucial link between conventional numerical simulations and immediate decision-making. Subsequently, the surrogate model is integrated into a realistic VR environment, aligned with the experimental forging setup. The study underscores the need and potential advantages of real-time digital twins in the forging field, emphasizing the bridging capability between numerical simulations and instant decision-making through predictive modeling and immersive virtual environments.