The student Julen Rosado Betolaza obtained an EXCELLENT CUM LAUDE

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The student Julen Rosado Betolaza obtained an EXCELLENT CUM LAUDE

THESIS

The student Julen Rosado Betolaza obtained an EXCELLENT CUM LAUDE

2026·02·25

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  • Thesis title: Digital-Twin: Milling Process Design and Modelling for Efficient Toolpaths

Court:

  • Presidency: José Antonio Yagüe Fabra (Universidad de Zaragoza)
  • Vocal: Eva María Rubio Alvir (UNED)
  • Vocal: Jorge Salguero Gómez (Universidad de Cádiz)
  • Vocal: Madalina Calamaz (ENSAM)
  • Secretary: Harry Yasir Otalora Ortega (Mondragon Unibertsitatea)

Abstract:

Manufacturing remains a cornerstone of the European economy, not only as a source of industrial competitiveness but also as a key pillar of employment and social stability. In the face of increasing global demand for productivity and efficiency, the machine-tool sector is undergoing a profound transformation through digitalization and data-driven technologies. One of the most promising developments in this space is the creation of Digital Twins—digital counterparts of physical assets that enhance product value, improve process understanding, and support informed decision-making. 

Despite significant advancements, the integration of Digital Twins into real-world machining environments remains limited. In current industrial practice, process planning in machining often relies on experience-based rules and static parameters, resulting in conservative, suboptimal cutting strategies. This research addresses this gap by developing a physics-based Digital Twin framework for peripheral milling, one of the most widely used and versatile machining operations. 

The work focuses on capturing the dynamic behaviour of the milling process by simulating how toolpaths—generated in CAM environments—evolve into physical interactions at the tool–workpiece interface. A discretization method is proposed to translate geometric trajectories into localized engagement conditions, enabling the calculation of cutting forces, tool deflections, and other transient phenomena. A mechanistic force model is calibrated to account for variable immersion and chip thickness, while structural dynamics are integrated to predict tool deviations and their impact on the final surface geometry. The framework is validated experimentally through force and surface dimensional measurement campaigns. 

Ultimately, this thesis contributes to closing the loop between digital design and physical execution in machining. By integrating in a trajectory geometry, force modelling, and dynamic response into a modular, unified and traceable Digital Twin environment, the research advances the state of the art in process modelling and moves toward smarter, more accurate, and physically grounded manufacturing systems.