Digital twin for joining mechanical structures in assembly processes

Abstract Ensuring geometric accuracy in joining mechanical structures is a key challenge in smart manufacturing, particularly during assembly. To improve assembly and joining accuracy, this paper employs digital twin technology, with a focus on high-fidelity digital modeling as a foundational step toward realizing digital twins–while treating bidirectional automated data flow as a future development direction. Digital twin models are developed for two representative joint types: threaded connections and spot-welded sheet metal structures, incorporating critical influences from manufacturing, assembly, and service phases. Compared to traditional idealized simulations, the proposed models enable more effective assembly process optimization and enhanced geometric quality control.