2021 IEEE 17th International Conference on Automation Science and Engineering (CASE)
August 23-27, 2021. Lyon, France
2021 17th IEEE International Conference on Automation Science and Engineering (CASE)
An adaptive evolutionary framework for the decision-making models
of digital twin machining system*
Shimin Liu, Member, IEEE, Hui Shen, Jie Li, Yuqian Lu, Member, IEEE, and Jinsong Bao Member,
2021 IEEE 17th International Conference on Automation Science and Engineering (CASE) | 978-1-6654-1873-7/21/$31.00 ©2021 IEEE | DOI: 10.1109/CASE49439.2021.9551595
IEEE
Abstract—Digital twin technology is the core promoter of
intelligent autonomous machining systems, which has been
gradually explored and applied in the machining field. The
digital twin system can observe, analyze, and control the
machining process in real-time by creating high fidelity virtual
entity of the physical entity. However, the current digital twin
system is usually customized for specific scenarios, which lacks
sufficient robustness. Remodeling may lead to poor modeling
effects and low modeling efficiency due to insufficient data. This
paper explores an adaptive evolution mechanism of the digital
twin decision-making model through incremental learning and
transfer learning. Besides, the specific implementation method is
concluded.
I. INTRODUCTION
As a new high fidelity replica method, digital twin
constructs the product process model adaptively and analyzes
the twin data based on the machining process to predict and
optimize the machining process [1]. Digital twin machining is
based on cutting modeling theory and digital manufacturing
technology to predict and optimize the machining process [2].
In machining, advanced data monitoring and machining
technology are used to monitor and extract features of
machine tools, workpieces and tools in real-time. Combined
with theoretical knowledge and machining experience, the
machining state is identified and monitored by artificial
intelligence technology [3]. Based on data analysis, reasoning
and decision-making, real-time optimization of cutting
parameters and equipment status adjustment can achieve the
ideal workpiece quality and machining efficiency. Therefore,
the digital twin has been gradually applied to the machining
process to control the machining process [4].
However, the disadvantage of the digital twin lies in its
high cost, and most of the decision-making modules of the
current system are based on the data analysis model [5].
Therefore, it is generally only used in a specific scenario [6].
*This work is financially supported in part by National Key Research and
Development Plan of China (Grant 2019YFB1706300), in part by the
Fundamental Research Funds for the Central Universities and Graduate
Student Innovation Fund of Donghua University (Grant No.
CUSF-DH-D-2020056). (Corresponding author: Jinsong Bao.)
Shimin Liu, Hui Shen, Jie Li and Jinsong Bao are with the College of
Mechanical Engineering, Donghua University, Shanghai 201620, PR China
(e-mail: 1182021@mail.dhu.edu.cn; sh15721584547@163.com;
jie.li@dhu.edu.cn; bao@ dhu.edu.cn).
Yuqian Lu, is with Department of Mechanical Engineering, The
University of Auckland, Auckland 1010, New Zealand (e-mail:
yuqian.lu@auckland.ac.nz).
978-0-7381-2503-9/21/$31.00 ©2021 IEEE
Authorized licensed use limited to: AIT Austrian Institute of Technology. Downloaded on February 16,2022 at 11:41:51 UTC from IEEE Xplore. Restrictions apply.
However, under the mode of multi-variety and small batch
production or when the digital twin system needs to be
established on a large scale, the following phenomena will
lead to remodeling:
(1) There are new kinds of parts or different quality
requirements;
(2) A new machining system different from the past needs
to build its digital twin systems.
These situations lead to the system mismatch in the direct
hard transplantation. The imbalance between the virtual
system and the physical system will occur, resulting in the
performance degradation of the system. However, the
construction of a data-driven digital twin system is complex,
and the following problems will appear when reconstructing
the model in line with the working conditions.
(1) The production process is affected by the suspension
of adjustment;
(2) Remodeling can lead to waste of resources;
(3) It is challenging to build the system because of the lack
of data.
Therefore, to solve the above problems, it is urgent to
automatically improve the generalization performance of
digital twins to adapt to various working conditions
automatically. The essence of a digital twin system is a
data-driven intelligent manufacturing system. This paper
proposes a digital twin adaptive evolutionary framework,
which endows different decision-making models with
evolutionary characteristics. With the integration of the
incremental learning method, the system can adaptively
improve its machining quality requirements with product
development. The idea of transfer learning is integrated to
realize the self-adaptation of the decision-making model in
machining. Through the above methods, the robustness of the
decision-making module of the digital twin system is
improved, and the time of system remodeling is reduced.
Therefore, the remainder of this paper is as follows: In
Section Ⅱ, the related work on the digital twin, incremental
learning, and transfer learning is summarized, and the
research gaps are highlighted; In section Ⅲ, the
decision-making model of the digital twin machining system
and its related theoretical framework are analyzed; In Section
Ⅳ, various scenarios in the machining process are analyzed,
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and corresponding evolutionary methods are proposed.
Finally, the methods in this paper are summarized.
II. RELATED WORK
With the development of artificial intelligence, big data,
cyber-physical systems and other technologies, the digital
twin has been highly concerned by the academic community
and carried out in-depth research. In this section, we will
review the related research and highlight the research gap.
A. Digital twin related applications
Grievers [1] put forward the digital twin concept in the
course of product lifecycle management in 2003. Since then,
relevant scholars have researched it one after another. They
summarized the concept, reference model and development
direction of digital twin [8][9][10][11]. Tao [12] pointed out
that the digital twin has great potential to change the
manufacturing industry. Tao et al. [13][14] put forward the
digital twin workshop concept, which applies digital twin to
product design, manufacturing and service. Zhu et al. [15]
proposed the digital twin management control framework and
applied it in assembly. Leng et al. [16]proposed a workshop
framework for glass production lines to realize rapid
automatic manufacturing. Zhou et al. [17] proposed a digital
twin manufacturing cell, which supports autonomous
manufacturing through intelligent perception, simulation,
understanding, prediction, optimization and control strategies.
Liu et al. [18] proposed a digital twin modeling method for the
machining process based on biological mimicry, changing
with the machining process. Sun et al. [19] proposed a method
of assembly and adjustment coupling based on the digital twin
to realize high-precision product assembly. Tong et al. [20]
proposed a real-time monitoring method based on Intelligent
Machine Tool (IMT) digital twin, which is used to visualize
and analyze processing trajectory, machining status, and
energy consumption. Kong et al. [21] proposed a data
construction method, which can adaptively design the data
construction framework according to the system's data
requirements.
B. Incremental learning and transfer learning
In the aspect of incremental learning, many scholars have
carried out applied research. Wang et al. [22] developed a
novel transfer and incremental soft-sensor scheme for batch
manufacturing processes with the support of multiple
historical process modes, termed mode-cloud here. Wang et
al. [23] designed a spatial correlation-based incremental
learning technique for spatiotemporal modeling to improve
accuracy and efficiency. Du et al. [24] proposed an online
cognitive, joint angle error compensation method based on
incremental learning to reduce joint angle error.
Many scholars apply the transfer learning method to the
production and manufacturing process. Wang et al. [25]
obtain the milling force prediction model after transfer based
on a small number of target field data set finetune. Compared
with the small sample data, the modeling accuracy is higher;
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Ye and Dai [26] applied transfer learning to time series data
prediction and solved it. They proposed a deep anti transfer
learning network for intelligent fault diagnosis of the machine,
realizes the recognition of new faults with high precision,
Zhou et al. [27] proposed a multi-level deep convolution
transfer learning method to solve the problem of machine fault
diagnosis under different working conditions; Cao et al. [28]
proposed feature transfer method to solve the problem of
machine fault diagnosis under variable conditions.
From the above literature review, it can be found that:
1) The existing research launched a deep exploration of the
modeling, analysis and prediction of the machining process.
These studies are mainly limited in their specific scenarios.
Whether these methods can be directly transplanted to other
scenarios is a scientific question. If transplanted directly, it
may lead to wrong decision results. Therefore, the robustness
of the digital twin needs to be studied to improve its
generalization performance.
2) At present, there are few kinds of research on the
generalization of digital twin systems. The decision accuracy
of the digital twin system mainly depends on its data-based
decision model. Incremental learning and transfer learning
can be integrated into the digital twin system to improve the
adaptability of the system to more scenarios.
Both of them play a significant role in improving the
robustness of the system and are further addressed in the
following sections.
III. DECISION MODEL OF THE DIGITAL TWIN SYSTEM
A. Digital twin machining system and demand analysis
The digital twin system based on data support can build a
new knowledge base to improve itself through continuous data
accumulation; it includes decision-making, implementation
and improvement. The digital twin machining unit can
understand, optimize and ultimately control the machining
process. As shown in Figure 1, the system includes four
spaces, and the cooperation and integration between them
make the digital twin machining system have a solid cognitive
and learning ability. Specifically, it includes the physical
space of the container of physical manufacturing resources,
the virtual space as the container of virtual manufacturing
resources such as virtual manufacturing equipment, the data
layer for storing historical data. The decision level is used to
analyze twin data to control the whole machining process.
The new generation of machining systems needs
generalization and robustness. The depth ability lies in the
high decision accuracy of the system. On the other hand, the
adaptive generalization ability of the system is also vital. It
can be seen from the above that most of the decision-making
models in digital twin machining systems are mainly data
analysis models. Therefore, the adaptive characteristics of
digital twin systems limited to data-driven can be divided into
two parts.
 1) The amount of data in the training set cannot ultimately model can exist. At this time, the construction of the model
include the data of the whole process, so no matter how to will be more time-consuming and laborious.
modify the model, the system still cannot improve the
adaptive ability of the decision-making model itself; B. Decision-making model in the whole life cycle of product
2) The change in the distribution of a training sample set manufacturing
can influence the model accuracy. This corresponds to the To overcome the above challenges, it is necessary to
accuracy problem of the decision-making model when the analyze the application of digital twin systems in the whole
elements such as tools, machine tools and parts change in life cycle of products and analyze the decision-making module
machining. of the machining process and the factors influencing the
machining model. From the development of a digital process
Machine
Data layer monitoring system to detect the life cycle of the parts, the
tool Physical space
Rules library whole process is shown in Figure 2.
Tool Fixture
Learning model
It can be seen from the above that the decision-making
Twin machine
Cognitive model model of digital twin machining system mainly exists in the
Virtual space
tool
design stage, machining stage and machining quality
Twin tool Twin fixture
inspection stage. Most of these models are based on the
Case library
amount of data. The corresponding forecasting,
Decision layer
decision-making, and control systems are formulated by
Processing status Decision making and
analyzing and mining historical data.
recognition module control
Cutting Cutting force Tool life
Tool status
temperature optimization optimization C. Classification of decision-making models in the digital
Parameter NC code
Cutting path Surface quality adjustment modification
Data support twin system
Cutting force Surface quality
...
monitoring optimization
The classification of the digital twin decision-making
system can be classified according to the way of its
Figure 1. The digital twin machining system construction. For example, the typical decision-making mode
can be divided into the expert system and learning system, and
However, most of the high-end manufacturing industries
the learning system can be divided into generative and
are multi-variety and small-batch manufacturing modes.
discriminant according to the method of learning. Therefore,
There are often different machining objects, different
according to the decision-making model structure, this paper
machining requirements and different machining
divides it into three categories: tree, line, graph, or network, as
technologies. When the tool, workpiece, and machine tool in
shown in Figure 3.
the system are changed, the problem of inapplicability of the
Design Machining Inspection
DM Process Process monitoring Quality online
optimization inspection

Process Control Online collection

Real machining Machining
planning command and prediction of
Cutting process quality
optimization based Virtual machining information
Feature on Simulation
recognition
Real-time Data Construction of
Requirement decision-making acquisition quality knowledge
analysis Real-time
simulation Parameter Information graph
Parameter
adjustment, error collection,
Path planning optimization
Machining compensation extraction and
error processing Quality knowledge
calculation Optimization graph analysis
Selection of Simulation result
production Abnormal decision
resources processing State analysis,
Result analysis alarm anomaly Digital twin Product quality
detection data inspection result
...

Digital twin
Figure 2. Intelligent machining process based on digital twin
As shown in Figure 3a, the tree structure mainly includes feasibility of the decision-making analysis method is a
decision trees and expert system models. This kind of model graphical method of intuitive use of probability analysis. This
mainly classifies the classified tagged data according to the branch of decision-making is graphically like the branch of a
specified requirements. They are mainly based on the tree.
probability of occurrence of various situations. To judge the

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 As shown in Figure 3b, this type is the generic model of incremental model and transfer model are integrated into the
probability graph model construction, mainly composed of system to improve its adaptive evolution.
various elements and various entities. Through the modeling
and analysis of various relationships, the network model A. Adaptive construction and evolution framework of digital
relationship is constructed. twin decision-making model.
As shown in Figure 3c, this type is mainly based on data to The adaptive evolution characteristics of the ideal system
build a transitive analysis network. The typical is the deep are as follows: 1) the established system can continuously
neural network. It is mainly composed of the analysis units in supplement the knowledge in its domain according to the
series. experience accumulation of machining tasks so as to improve
the accuracy of its model; 2) the established system can
complete similar work according to its domain skills. The
function of the decision-making model in the manufacturing
system is mainly divided into three parts: health monitoring,
condition monitoring and quality prediction. These algorithms
contain a large number of their own models, which need to be
timely analyzed according to the specific situation of the
scene. Therefore, the depth and breadth of the system need to
be improved.
a) Tree structure b) Network structure
The adaptive evolutionary framework of digital twin
c) linear structure decision-making models is shown in Figure 4. The framework
has the following characteristics:
Figure 3. The structure of the digital twin decision-making model
1) The system collects data at the time of running, and then
IV. ADAPTIVE EVOLUTIONARY METHOD FOR THE DIGITAL it is used to improve the decision-making model.
TWIN DECISION-MAKING MODEL 2) When the system cannot provide an effective
From the above analysis, it can be seen that the core decision-making model, according to the corresponding task
driving force of the digital twin system lies in its conditions, the decision-making model meeting the machining
decision-making model. Most of these decision-making task is reconstructed.
models are based on a data analysis model, so the
generalization performance of the digital twin system depends
on its decision-making model. In this section, the ideas of the
Machining process

Process-1 Process-2 Process-3 Process-1

T
D
Blank Data acquisition Data acquisition Product

Machine Model
Quality model
Tool Machine tool fault reconstruction
Tool health construction
New task

breakage prediction tool health diagnosis

warning prediction model
Residual life Quality Quality T
Tool remaining life prediction
prediction of analysis
prediction
machine tool

Decision model layer

New data

Original data

New model

Figure 4. The adaptive evolutionary framework of digital twin decision-making models

suitable for people. It is mainly applicable to the cloud sharing
B. Model self-evolution under data increment platform or the increase of data volume during machining.
The idea of data increment is to form the field machining
data of each product application into experience data and As shown in Figure 5, the system cannot identify the new
input it into the training set continuously so as to improve the categories that the training sample set cannot represent
performance of the system. This kind of scene is mainly because the actual industrial process is in constant change.

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The traditional decision-making model lacks the target task, choose the appropriate reconstruction method.
corresponding recognition mechanism, so it can only classify The main method of reconstruction is transfer learning. The
the new class samples to the known class, which leads to the general idea of the transfer model can be divided into three
wrong classification results. When a new category problem categories: inductive transfer learning, transductive transfer
occurs, the incremental learning method first uses the expert learning and unsupervised transfer learning, as shown in Table
knowledge to identify its real category; then, it uses the II.
marked samples to update the classification model offline, and
then continues to put the updated model into online use. Due TABLE I. ANALYSIS OF MODEL FAILURE UNDER DIRECT REUSE
to the production requirements, many actual industrial
processes (primarily process industrial processes) usually Event Decision-making Reasons for not reusing
need to maintain continuous operation for an extended period. model
Because offline labeling of samples and offline updating of Replace Tool wear monitoring The range of cutting force,
models take a long time, incremental learning is not suitable different types of Tool life prediction vibration, heat and machine
for fundamental industrial processes with high real-time and tools Tool breakage warning tool electrical signal is
long continuity. In other words, if we can identify new different
samples online, it is of great significance to the process Replace Machine tool fault The composition of the data
diagnosis of the actual industrial process. different types of diagnosis signal is different
Sample space
Category 1 Category 2 Category 3 Category n machine tools Remaining life
prediction of machine
tool
Training data
Develop new Machining strategy The composition of
types of products recommendation manufacturing features is
Process data
New category 1 New category 2 New category 3 New category n
Incremental data different
Changes in Changes in quality mix The target domain tasks are
Model evolution
machining requirements different
technology Different Different target domains
combinations of
quality characteristics

Figure 5. Incremental evolution method of the digital twin model

Source domain
C. Construction method of the decision-making model due to
Source domain
model change
As shown in Table I, when the basic elements of the
model building, such as replacing new tools or machine tools, Model
transfer
appear, the previous model cannot be used directly, or the
accuracy drops significantly. The usual way is to retrain the Target domain
model, and the data model itself is more dependent on the
breadth of the data itself. Recollecting data to build the model Target domain

will waste many resources. Therefore, this paper proposes

using the transfer method to build the decision-making model Figure 6. Transfer method of the digital twin decision-making model
of the digital twin system, as shown in Figure 6.
Given the above situation, the system first captures the
dynamic characteristics in machining. After analyzing the

TABLE II. DIFFERENT SETTINGS OF MODEL TRANSFER METHODS FOR DIFFERENT APPLICATION SCENARIOS
Decision-making model Inductive Transfer Learning Transductive Transfer Learning Unsupervised Transfer Learning
Tool breakage warning √
Tool health prediction √
Machine tool health prediction √ √
Tool remaining life prediction √ √
Residual life prediction of machine tool √ √
Quality prediction √ √
Quality analysis √ √
Machine tool fault diagnosis model √

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V. CONCLUSION
The digital twin application in machining and
manufacturing is an effective means to break through the
bottleneck of product machining quality and accuracy. Given
the lack of functional generalization characteristics of the
current digital twin model, this paper analyzes the
decision-making model categories of the digital twin system.
Combined with the current development direction of
intelligent manufacturing, the interconnection mechanism of
the digital twin workshop is proposed, and the adaptive
evolution framework of the digital twin system is given. The
main contributions of this paper are as follows.
(1) This paper analyzes the nodes that need to build a
decision-making model during the digital twin machining
process.
(2) This paper proposes a digital twin adaptive evolution
framework to improve the generalization and robustness of
the system.
The future research directions include in-depth application
in each decision-making model. Besides, the construction of a
digital twin robustness evaluation system can also promote the
application of a digital twin system.
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