Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

A review on simulation in digital twin for aerospace, manufacturing

a r t i c l e i n f o a b s t r a c t

Article history: The Digital Twin (DT) is known as a computer-generated equivalent of a physical system. It is used to
Received 8 June 2020 simulates for different objectives through the real-time harmonization of data received from the field.
Received in revised form 20 June 2020 The prime interpretation of DT is very close link to simulation technique and software used. This relation
Accepted 23 June 2020
can be viewed in two approaches viz., (i) DT is model to present the system based upon the various kinds
Available online xxxx
of simulations techniques and tools and, (ii) DT as simulation of the system itself. In the aerospace, sim-
ulations replicate the continuous time history of flights, producing vast amount of data of simulations in
Keywords:
order to recognize what the aircraft has undergone and to project forthcoming maintenance require-
Simulation
Digital Twin
ments and intrusions using various applications based simulation techniques, Computational Fluid
Literature Review Dynamics (CFD), Computer-Aided Engineering (CAE), Finite Element Methods (FEM) and Monte Carlo
Digitization simulation. In case of manufacturing, the simulation helps to mimic the complex behavior of production
Industry 4.0 procedures considering the effects of design constraints, human interventions, and any other external
disturbances. In robotics, the simulation is mainly concern with the virtual commissioning of task in
order to improve the control algorithms for robots in the course of development stage. In this paper, var-
ious recent contributions on simulation-based DT and DT-based simulation models proposed by
researchers in the field of aerospace, manufacturing and robotics have been presented. The motivation
behind this review is to pave the way and clarify the conceptual foundations on the adaptation of simu-
lation techniques and software to develop DT for various applications.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the 2nd International Con-
ference on Future Learning Aspects of Mechanical Engineering.

1. Introduction not merely a large collection of all digital things; it is having a well-
structured architecture and the entire components are linked as
As per the Business Directory, digitization is an ‘‘Integration of well as it has metainformation and semantics [19]. In fact, the DT
digital technologies into everyday life by the digitization of everything is the cutting-edge approach for modeling, optimization, and
that can be digitized”. In an industrial context, it is the increase in simulation.
creation, use and storage of digital things in the life cycle of prod- During 1960s, the simulation was limited to very specific topics
ucts and systems. These digital things possess a complete data and by experts such as mechanic. After 1985, the simulation was used
information which is required by various investors as well as it cre- as basic and standard tools in order to resolve some specific design
ate a massive storage of digital data. In fact, the computational and engineering problems, for instance fluid dynamics. Subse-
power has been increased drastically and it is readily available quently, the simulation-based system design was started around
throughout the world. Owing to this, the simulation technique 2000 onwards in which simulation is a general methodology for
has been empowered to solve more complex problems, integrate ‘‘multi-level and multi-disciplinary systems” having greater func-
the models of different designs and accurately predict the behavior tional varieties and applications, for example ‘‘Model Based System
of systems. These high-level simulations are normally termed as a Engineering” – MBSE concept [19]. However, 2015 onwards simula-
Digital Twin (DT) corresponding to the system they modeled. DT is tion started playing an important role for essential activities of sys-
tems through the continuous support beside the entire cycle, for
⇑ Corresponding author.
example, assisting function and service through the immediate
E-mail address: [email protected] (R.K. Phanden).
and direct connection to the operational data. Offering simulation

https://doi.org/10.1016/j.matpr.2020.06.446
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the 2nd International Conference on Future Learning Aspects of Mechanical Engineering.

Please cite this article as: R. K. Phanden, P. Sharma and A. Dubey, A review on simulation in digital twin for aerospace, manufacturing and robotics, Materi-
als Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.06.446
2 R.K. Phanden et al. / Materials Today: Proceedings xxx (xxxx) xxx

to the ensuing life-cycle stages corresponding to the system func- as maintenance and fleet) in order to accurately reflect the whole
tionality and core product, for instance, strengthening the opera- life as a flying twin which helps to facilitate the excellent trust
tion by simulation driven assistance, is the next big trend in and safely levels. DT is highly accurate and practical which can
simulation. The fine tuning of simulation software to yield an opti- be independently as well as dependently considered for any sys-
mized performance is the one of the key challenges in DT. This fine tem and subsystem of vehicle such as airframe, life support, energy
calibration of simulation software help DT to simulate the activi- storage and propulsion, thermal protection, avionics and many
ties much faster than the happenings in actual world. Subse- more. In addition, the DT encourage to integrate the material pro-
quently, the DT can not only be used during system design but cessing techniques with design of materials since the manufactur-
also during run time to predict system behavior online [8]. Details ing glitches may seriously affect the vehicle [16]. Glaessgen and
on the concept of DT, its definitions and history are the beyond the Stargel [9] proposed DT-based simulation for monitoring the man-
scope of this article. Readers may refer [16] for it. ufacturing anomalies for health management and maintenance
In fact, the DT was invented and adopted in the aerospace history for aeronautics and space applications. Reifsnider and
domain of research and development. Recently, the manufacturing Majumdar [17] presented a digital mirror (DT) of life of flying
field has embraced the DT concept. However, the literature depicts physical twin to predict the microcracks at early stage using inte-
that the concept of DT in the manufacturing is at the very early grated simulation and on-board health management system. They
stage. In this direction, Cyber Physical System (CPS) opened the have discussed a response integral method and dielectric compli-
routes to an additional use, out of prognostics and diagnostics ance as a foundation for stimulated simulation.
objectives. CPS has setup the meaning of DT for the production ‘‘Structural Health Monitoring” – SHM system is used to assess
engineering domain. Many windows have been unlocked such as and analyze in-situ data of up-to-date capability of structural ele-
improved support to health analyses in order to enhance the plan- ments in order to make its planned functionality successful. In this
ning and maintenance functions [9,23,10,17,5,21,6,7,12], creating a direction, Bazilevs et al. [5] adopted ‘‘Dynamic Data Driven Applica-
digital mirror of physical resources [15,19,3], Schluse and Ross- tion System” called DDDAS in which computational model of sys-
mann [20,1,11], improved decision making capabilities for various tem was updated dynamically. They proposed FEM simulation-
statistical and engineering analyses [18,8,13,4]. In addition, the DT based DT for fatigue-damage prediction. They combined the mod-
in its original sense appears as a tool to help in predicting of fail- els of fatigue-damage i.e. ‘‘Iso-Geometric Analysis” – IGA of thin-
ures of system during lifecycle on the basis of data received from shell structures with the SHM to build up computational handling
ground level through the sensors in the aerospace engineering architecture. This combination was helpful to predict fatigue-
domain [9,5,21], Kraft [13]. One of the very important and first damage in a full-scale laminated composite structure. They consid-
understanding of DT is the underground relation to simulation ered a fatigue test of wind-turbine blade and concluded the predic-
tools that can be noticed in two ways viz., (i) DT is model to present tion of damage zone formation and evolution, eventually leading to
the system based upon the various kinds of simulations techniques blade failure. IGA is a FEM based simulation based on, animations,
and tools [23,10,17,19,5,20,21,4,11] and, (ii) DT as the simulation computer graphics and geometry of Computer Aided Design (CAD)
of the system itself [9,15,8,13]. Even though, the simulation is in model. IGA possess high order of continuity as compare to a regular
close connection and an important aspect associated with DT fun- FEM technique which is helpful in computational mechanics.
damentals, there are many authors who do not mention it [18,3,1]. DDDAS needs few active simulations to trial the stress conditions
Notwithstanding, of close relation among DT and simulation con- in structure for development of fatigue-damage status.
cepts, many researchers highlight distinct uses and physical char- The mechanical structure of an aircraft is known as airframe.
acteristics. Thus, it is important to explore the simulation aspects Airframe Digital Twin (ADT) is a tail number (i.e. aircraft registra-
in DT for better understanding of their relationship from proposed tion number). In fact, ADT is computation model of an aircraft. It
frameworks and direction of research viewpoint. In this direction, a includes sub-models of electronics, propulsion systems, flight con-
review of the contributions on simulation-based DT and DT-based trols etc. ADT possessed a high degree of integration among sub-
simulation has been presented for aerospace, manufacturing, and models in term of level of fidelity and computing uncertainties as
robotics applications. A review of the contributions on this would compare to the conventional structural modeling techniques. Tue-
be highly beneficial, to pave the way and clarify the conceptual gel [23] developed virtual health sensor-based DT using FEM and
foundations for future research works on the adaptation of simula- Montecarlo simulations with the help of Damage and Durability
tion techniques and simulation software to develop DT for various Simulator (DDSim) simulation software to forecast the mainte-
applications. Subsequent sections of this article discuss the simula- nance needs. They have proposed ADT to decrease maintenance
tion and DT in aerospace, manufacturing, and robotics. At the end, cost by decreasing uncertainty and increasing service information
conclusions are drawn. using Bayesian updating method.
Gockel et al. [10] proposed a strategy called ‘‘Condition Based
Maintenance Plus Structural Integrity” (CBM + SI) to generate high-
2. Simulation and DT in aerospace level fidelity airframe stresses for an aircraft by capturing the com-
plete flight data using a recorder. This data was used to fly a CFD
In the aerospace, simulations replicate the continuous time his- model in order to find time history of aerodynamics load and then
tory of flights, producing vast amount of data of simulations in applying this time history to ADT. FEM based ABAQUS software
order to recognize what the aircraft has undergone and to project was used to analysis temperature, stresses and strains. Ten points
forthcoming maintenance requirements and intrusions using vari- as well as flight routes were used for CFD simulation using Rocstar
ous applications based simulation techniques, Computational Fluid Simulation Suite. Authors concluded that only ten points in the sky
Dynamics (CFD), Computer-Aided Engineering (CAE), Finite Ele- were simulated independently, with linear-elastic response and
ment Methods (FEM) and Monte Carlo simulation only 0.1 s of flow simulated in CFD. A ready-made commercial soft-
[9,23,10,17,5,4]. A very few researchers underline that the simula- ware on a normal PC machine was used for structural response
tion have to relate with the on-board sensors and devices to setup analysis in order to exploit parallel processing.
a constant harmonization along the ground situations [17]. Integrating System Models and MBSE helps to set up the coor-
From the aerospace viewpoint, DT can be defined as an integrat- dination among various disciplines such as mechanical, electrical,
ing tool for a very-high-level realistic simulation setup with an on- verification, software as well as other aspects of models and archi-
board health platform of vehicle having all type of past data (such tectures throughout the lifecycle of any system. This approach can

Please cite this article as: R. K. Phanden, P. Sharma and A. Dubey, A review on simulation in digital twin for aerospace, manufacturing and robotics, Materi-
als Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.06.446
 R.K. Phanden et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

be termed as Total System Model (TSM) with a digital outline (DT). cast the crack propagation. Gabor et al. [8] proposed DT based
In fact, this combination has gained a lot of attention from simulation to optimize system behaviors during design phase in
researchers and practitioners since it involves several vendor tools a smart CPS. Arisoy et al. [2] proposed HMI simulation-based DT
as well as structurally regulated repositories process. In this direc- for layout optimization. They introduced a data-driven approach
tion, Bajaj et al. [4] proposed the integration of system engineering for estimating natural grasp point locations on objects that human
and mechanical design in which the CAE simulation-based DT was interact with in industrial applications. Schroder et al. (2016) pro-
developed using Mathematica and MATLABÓ/Simulink. The pro- posed data exchange simulation-based DT to monitor physical
posed TSM combine the system architecture model (SysML) with entity.
CAD, CAE, PLM, Application Lifecycle Management (ALM), Simula- The development of DTs for manufacturing is the next step for
tions methods, Project Management etc. They proposed Syndeia continuing research on Virtual Factories (VF). In fact, this is beyond
MBSE software platform (of InterCAXÓ) for seamless communica- the digitization of plant. The shop floor resources and activities are
tion among systems engineering and various disciplines. to integrate with the digital models by updating and simulating the
Smarslok et al. [22] proposed numerical simulation-based DT complete production functionality while production for whole life-
models for damage and life prediction including failure to make cycle of products and processes [14]. In general, the data and infor-
decisions in condition-based maintenance. They have integrated mation gathered during the design stage of is not utilized at the
a variety of uncertainties in a connected hypersonic structural sim- operating stage. Although, the information of design is highly
ulation. Wang et al. [25] proposed FEM and Montecarlo important for production stage in order to help in decision making
simulation-based DT for diagnostics and prognostics of aircrafts. process at the floor level as well as to easy the performance assess-
They applied a fatigue mechanics and Extended Kalman Particle ment. The research on VF need a structured and suitable semantic
Filters (EKF) for layout optimization and Human-Machine Inter- data model. In this direction, the semantic ‘‘Virtual Factory Data
face (HMI) interaction simulation. Model” – VFDM has been developed by [24]. They proposed a holis-
Ríos et al [18] proposed Dassault Systemès (DS) V6 simulation- tic way of production system based on consistent and stretchable
based DT for aircraft mockup to support design. They presented a criterion for collective description of various entities like processes,
collaborative model for the creation of an aircraft named ‘‘indus- resources, buildings, and products of the factory.
trial Digital Mock-Up” iDMU, verified by a functional model and
an iDMU dataset structure. DS V6 solution comprises several appli-
cations namely DELMIAÓ manufacturing hub, DELMIAÓ process 4. Simulation and DT in robotics
engineering (DPE), DELMIAÓ digital process for manufacturing
(DPM) and DELMIAÓ work instructions planning (WKI); and com- In robotics, the simulation is mainly concern with the virtual
bines a manufacturing database with individual files. DS V6 frame- commissioning of task in order to improve the control algorithms
work provides a common database to store and retrieve for robots in the course of development stage [20,11]. Simulation
industrialization data, facilitating the adoption of the parent pro- is the most effective source of information for robotics to prepare
duct avatar proposed by Hribernik et al. (2006). strategic plans, forecast, scale and measurements as well as to test
Simulation based prognosis of structural composites need a various setting environments for different disciplines to improve
deep knowledge and understanding of mathematics for the process the performance with respect to the cost and time. In general,
of interactions, material phase change over phenomenon owing to the approaches for robot simulation is based on kinematic body
mechanical loadings and unloading. Majumdar et al. [15] proposed dynamics. Many good simulation software’s are available for com-
DT based simulation to investigate long term behavior of structural mercial purpose. However, the most useful and well-known robot
composites and their synergistic response under multiple environ- simulation software’s are; (i) GAZEBOÓ and V-REPÓ focused on
mental conditions. They studied the effects on structural perfor- sensors and image based assemble systems, (ii) ROBOTRANÓ a
mance in multi-physical environment (electrical field) which physics-based symbolic software to model and analyze multi-
produce microstructural changes in structural composites. They body systems, and (iii) ROBCADÓ from SIMSOL working in associ-
conclude that increasing magnitude of electrical current can cause ation with SIEMENSÓ. These simulation tools are much effective
significant degradation. On the other hand, multi-physical behav- and adaptable for planning and optimizing assembly system, robot
ior depends on local microstructure and resulting anisotropic nat- factory and sensors.
ure of composite material. Virtual Testbeds (VT) and DT (eRobotics) directs towards an ‘‘ex-
Cerrone et al. [6] proposed a production-level simulation-based perimentable DT” which is a simulation-based development-and-
DT to monitor crack paths by filling information gaps which helps operation of an intricated system. The testbed-based approach is
to predict crack path. FEM models of as-manufactured specimens very helpful to improve the traditional simulation methods. VT
are generated and subsequently analyzed to resolve the crack- facilitate the assessment of full technical system in its nature.
path ambiguity. DT specimens are modeled and simulated in However, a normal simulation technique analyzes only few fea-
FEM based Abaqus/Explicit software package, to resolve crack path tures and characteristics of an application. So, the VTs are well fit-
ambiguity in the ‘‘Sandia Fracture Challenge” – SFC geometry. ted to embody the DTs. For robotics, there is a need of an individual
and all-inclusive as well as integrated 3D simulation architecture
in order to apply all methods. In this direction, Schluse and Ross-
3. Simulation and DT in manufacturing mann [20] presented MATLABÓ/Simulink simulation-based DT
for virtual commissioning having simulation at system level during
In manufacturing, the main objectives of simulation are to rep- design. The authors shown applications for on-orbit servicing,
resent the complex behavior of the system, also considering the localization of forest machines, driver assistance systems and an
possible consequences of external factors, human interactions industrial automation. They stated that the proposed approach is
and design constraints [19,8,2]. Rosen et al. [19] proposed capable to integrate virtually any type of simulation. They have
simulation-based DT for complex behavior of production in pro- illustrated the micro kernel called ‘‘Versatile Simulation Database”
duct life cycle. The proposed framework combining the real-life – VSD which is object-oriented real-time database having a narra-
data with the simulation models from design to give predictions tive of basic simulation model.
based on the realistic data. Kraft [13] proposed manned flight sim- Mating of components is a major production step in automated
ulators DT for engineering analyses and decision making to fore- assembly lines. Many aspects in mating two parts can be reduced

Please cite this article as: R. K. Phanden, P. Sharma and A. Dubey, A review on simulation in digital twin for aerospace, manufacturing and robotics, Materi-
als Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.06.446
4 R.K. Phanden et al. / Materials Today: Proceedings xxx (xxxx) xxx

to a peg-in-hole problem. When the parts are fitted to each other, It can be easily concluded that it is still to be explored on the
jamming may occur, leading to assembly failure or damage to the integration of simulation and DT in the development process as
parts, to the robot, or to its environment. Therefore, an intrinsically well as in the overall life cycle of a system. Since the DT have to
safe environment is required for the development and testing of accurately simulate every part of system hardware. It may only
new algorithms. Grinshpun, et al. [11] proposed ‘‘Virtual Environ- be decided after testing multiple prototypes we are left with a typ-
ment and Robotic Simulation” – VEROSIM based DT to apply and ical chicken-and-egg problem.
optimize the algorithm for control of robots for virtual commis- It is worth to mention that the cost of computational power is
sioning. They presented a workflow for developing control algo- still decreasing with technological advancements in hardware. In
rithms by means of a VT. Initially, they have created a virtual contrast, a simulation model with a refined encoding which can
setup to test and optimize the algorithm in simulation. This setup easily configure with the real environment is allow us to test the
comprises a DT of the used physical manipulator and an simulation of real observations and thus improve the performance
application-oriented virtual environment for its operation. Then of actual system. In addition, it should allow to integrate multiple
an algorithm for peg-in-hole insertion is developed that copes suc- real models and compatible with any version of a DT which may be
cessfully with peg and hole fitted to each other with small clear- plugged into the system.
ances. This algorithm is tested and validated using the DT within
simulation. After its successfully validation in a VT, the algorithm
CRediT authorship contribution statement
is transferred to a physical setup containing the physical KUKA
LWR4 manipulator and manufactured assembly parts.
Rakesh Kumar Phanden: Conceptualization, Writing - review
& editing, Supervision. Priavrat Sharma: Writing - original draft,
Formal analysis, Project administration. Anubhav Dubey: Writing
- original draft, Formal analysis, Project administration.
5. Conclusions

It can be concluded that the simulation and DT technologies can Declaration of Competing Interest
execute virtual simulations models, but they are not same. A sim-
ulation in CAD/CAM/CAE are useful for product design, manufac- The authors declare that they have no known competing finan-
turing, and analysis. DT have much more to do as compare to the cial interests or personal relationships that could have appeared
traditional simulation. A virtual simulation model becomes a DT to influence the work reported in this paper.
once the product is ready to use. For instance, (i) CAD simulation
is static till a designer introduces a new parameter. While a DT References
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Please cite this article as: R. K. Phanden, P. Sharma and A. Dubey, A review on simulation in digital twin for aerospace, manufacturing and robotics, Materi-
als Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.06.446