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Applied Sciences
Volume 15
Issue 10
10.3390/app15105549
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Article

Development of a Small CNC Machining Center for Physical Implementation and a Digital Twin

by
Claudiu-Damian Petru
,
Fineas Morariu
,
Radu-Eugen Breaz
*,
Mihai Crenganiș
,
Sever-Gabriel Racz
,
Claudia-Emilia Gîrjob
,
Alexandru Bârsan
and
Cristina-Maria Biriș
Engineering Faculty, Lucian Blaga University of Sibiu, 550024 Sibiu, Romania
*
Author to whom correspondence should be addressed.
Appl. Sci. 2025, 15(10), 5549; https://doi.org/10.3390/app15105549
Submission received: 16 April 2025 / Revised: 13 May 2025 / Accepted: 14 May 2025 / Published: 15 May 2025
(This article belongs to the Special Issue Advanced Digital Design and Intelligent Manufacturing)
Versions Notes

Featured Application

The results of this research can be used to develop low-cost, open-architecture CNC (computer numerical control) systems and digital twins that make them easier to use and continually improve their performance. These CNC systems can be used for applications such as the engraving or milling of soft materials.

Abstract

This work aimed to develop both a real implementation and a digital twin for a small CNC machining center. The X-, Y-, and Z-axes feed systems were realized as closed-loop motion loops with DC servo motors and encoders. Motion control was provided by Arduino boards and Pololu motor drivers. A simulation study of the step response parameters was carried out, and then the positioning regime was studied, followed by the two-axis simultaneous motion regime (circular interpolation). This study, based on a hybrid simulation diagram realized in Simulink–Simscape, allowed a preliminary tuning of the PID (proportional integral derivative) controllers. Next, the CAE (computer-aided engineering) simulation diagram was complemented with the CAM (computer-aided manufacturing) simulation interface, the two together forming an integrated digital twin system. To validate the contouring performance of the proposed CNC system, a circular groove with an outer diameter of 31 mm and an inner diameter of 29 mm was machined using a 1 mm cylindrical end mill. The trajectory followed the simulated 30 mm circular path. Two sets of controller parameters were applied. Dimensional accuracy was verified using a GOM Atos Core 200 optical scanner and evaluated in GOM Inspect Suite 2020. The results demonstrated good agreement between simulation and physical execution, validating the PID tuning and system accuracy.
Keywords: Arduino; CNC; digital twins; circular interpolation; motion control; PID controller; simulation Arduino; CNC; digital twins; circular interpolation; motion control; PID controller; simulation

Share and Cite

MDPI and ACS Style

Petru, C.-D.; Morariu, F.; Breaz, R.-E.; Crenganiș, M.; Racz, S.-G.; Gîrjob, C.-E.; Bârsan, A.; Biriș, C.-M. Development of a Small CNC Machining Center for Physical Implementation and a Digital Twin. Appl. Sci. 2025, 15, 5549. https://doi.org/10.3390/app15105549

AMA Style

Petru C-D, Morariu F, Breaz R-E, Crenganiș M, Racz S-G, Gîrjob C-E, Bârsan A, Biriș C-M. Development of a Small CNC Machining Center for Physical Implementation and a Digital Twin. Applied Sciences. 2025; 15(10):5549. https://doi.org/10.3390/app15105549

Chicago/Turabian Style

Petru, Claudiu-Damian, Fineas Morariu, Radu-Eugen Breaz, Mihai Crenganiș, Sever-Gabriel Racz, Claudia-Emilia Gîrjob, Alexandru Bârsan, and Cristina-Maria Biriș. 2025. "Development of a Small CNC Machining Center for Physical Implementation and a Digital Twin" Applied Sciences 15, no. 10: 5549. https://doi.org/10.3390/app15105549

APA Style

Petru, C.-D., Morariu, F., Breaz, R.-E., Crenganiș, M., Racz, S.-G., Gîrjob, C.-E., Bârsan, A., & Biriș, C.-M. (2025). Development of a Small CNC Machining Center for Physical Implementation and a Digital Twin. Applied Sciences, 15(10), 5549. https://doi.org/10.3390/app15105549

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