In this publication, the application of an implemented Digital Twin (DT) framework is presented by orchestration of CAM-integrated and containerized technology models carrying out FEM-coupled simulations for the finishing process of a simplified blade integrated disk (blisk) demonstrator. As a case study, the continuous acquisition, processing and usage of virtual process planning and simulation data as well as real machine and sensor data along the value chain is presented. The use case demonstrates the successful application of the underlying DT framework implementation for the prediction of the continuously changing dynamic behavior of the workpiece and according stable spindle speeds in the process planning phase as well as their validation in the actual manufacturing phase.

This paper presents a CFD-based method for the aerodynamic design of a high-pressure compressor rotor blisk, taking into account manufacturing constraints. Focus is placed on the influence of geometric deviations caused by the dynamic constraints of the milling machine. Special attention is given to the leading edge region of the blade, where high curvature results in increased sensitivity in both aerodynamic behavior and manufacturability. The generic blisk geometry on which this study is based is characterized by an elliptical leading edge. For the optimization, the leading edge is described by Bézier curves that transition smoothly to the suction and pressure sides with continuous curvature and a non-dimensional length ratio. In steady-state RANS parameter studies, the length ratio is systematically varied while the chord length is kept constant. For the aerodynamic evaluation of the design’s key performance parameters such as blade pressure distribution, total pressure loss and compressor efficiency are considered. To evaluate the machine dynamics for a given design, compliance with the nominal feed rate and the deviation between the planned and actual tool tip positions were used as evaluation parameters. Compared to the reference geometry with an elliptical leading edge, the purely aerodynamic optimization achieved an isentropic efficiency improvement of +0.24 percentage points in the aerodynamic design point and a profile deviation improvement of $-3$$\mu$m in the 99th quantile. The interdisciplinary optimization achieved an improvement of +0.20 percentage points and $-30$$\mathrm{\mu }$m, respectively. This comparative study illustrates the potential of multidisciplinary design approaches that balance aerodynamic performance goals with manufacturability via a novel approach for Design-to-Manufacture-to-Design.

As the third generation of biomaterials, magnesium (Mg) is a promising candidate for biomedical applications. The traditional manufacturing methods are unable to produce complex geometries required for implants. Advancing manufacturing technologies could open a new window of opportunity for Mg alloys. This study aimed to develop an end-to-end manufacturing solution that enables the

Over the past decades, global air traffic has increased continuously, with passenger kilometers roughly doubling every fifteen to twenty years, and this trend is estimated to continue, with some adjustments due to COVID-19 impact. In response to the resulting environmental challenges, the European initiatives Flightpath 2050 and Clean Sky serve as central drivers of technological development aimed at achieving ambitious sustainability goals. Flightpath 2050 targets, relative to a reference engine from the year 2000, include a 75% reduction in CO₂ emissions per passenger kilometer, a 90% reduction in NO_x emissions, and a 65% reduction in noise emissions. These objectives highlight the urgent need for emission reduction strategies across all manufacturing domains, including turbine component production. This study evaluates the environmental impacts of the preturning and roughing operations employed in turbine disk production. The analysis focuses on these specific processes rather than the entire product, as the approach of process-level Life Cycle Assessments (LCA) are more universally applicable across different products, and their systematic combination can ultimately form a comprehensive product-level LCA. Operational data, such as energy usage, cooling lubricants, and compressed air, were gathered and processed from the equipment involved in manufacturing. The collected data were analyzed and modeled in Spheras life cycle assessment software LCA for Experts (version 10.9.0.20) to quantify the environmental effects of each process. The findings of the current research emphasize notable patterns of resource utilization and their respective environmental impacts. Furthermore, the Industrial Digital Twin Association (IDTA) Product Carbon Footprint (PCF) template was utilized to present the findings in a standardized manner, enabling effective data transfer between stakeholders. The results demonstrate the critical need to leverage machine data for sustainability analysis, providing inputs for industry practice enhancement and progress toward better environmental performance.