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Abstract <p>Polymer-bonded explosives (PBXs) is widely used in the defense and aerospace industries, and diamond wire sawing is commonly adopted for their machining due to its high cutting efficiency and material utilization. However, the flammable and explosive nature of PBXs makes real-time temperature monitoring during processing critical for ensuring operational safety. To address this challenge, this study proposes a digital twin–driven temperature monitoring system for the wire sawing process. A system framework is first established, and a split-frame rendering strategy is introduced to enable real-time and smooth visualization of the temperature field. Temperature field data are obtained through finite element simulation, and a PBX substitute material widely used in related studies is employed in experiments to mitigate safety risks, the experimental results validate the accuracy of the simulation. Based on the simulation data, a surrogate model is developed by integrating the self-attention mechanism into a fully connected neural network (FCNN), enabling accurate and efficient temperature prediction. Finally, the performance of both the surrogate model and the temperature monitoring system is systematically evaluated. The model achieves an R<sup>2</sup> value exceeding 0.99, with MAE and RMSE below 0.1℃. In addition, the monitoring system maintains a stable visualization frame rate of approximately 60 FPS and provides real-time information such as maximum temperature and safety status. Overall, this study offers a novel and safe solution for temperature monitoring during PBXs wire sawing and provides a new approach for enhancing the safety and intelligence of energetic materials machining processes.</p> Highlights <p>• A digital twin-driven temperature monitoring system for wire sawing is proposed.</p> <p>• The surrogate model enables accurate and efficient temperature field prediction.</p> <p>• Real-time temperature visualization is achieved with stable rendering performance.</p> <p>• The approach improves safety and intelligence in machining energetic materials.</p>

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Research on temperature monitoring system for wire sawing process of polymer-bonded explosives substitute material driven by digital twin

  • 期刊论文

  • 发表日期：

    2026年2月28日

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  • Shipeng Li,
  • Han Lv,
  • Hao Li,
  • Zhaoxin Hou,
  • Qing Zhao,
  • Xuda Qin,
  • Guoyu Fu

摘要

Abstract

Polymer-bonded explosives (PBXs) is widely used in the defense and aerospace industries, and diamond wire sawing is commonly adopted for their machining due to its high cutting efficiency and material utilization. However, the flammable and explosive nature of PBXs makes real-time temperature monitoring during processing critical for ensuring operational safety. To address this challenge, this study proposes a digital twin–driven temperature monitoring system for the wire sawing process. A system framework is first established, and a split-frame rendering strategy is introduced to enable real-time and smooth visualization of the temperature field. Temperature field data are obtained through finite element simulation, and a PBX substitute material widely used in related studies is employed in experiments to mitigate safety risks, the experimental results validate the accuracy of the simulation. Based on the simulation data, a surrogate model is developed by integrating the self-attention mechanism into a fully connected neural network (FCNN), enabling accurate and efficient temperature prediction. Finally, the performance of both the surrogate model and the temperature monitoring system is systematically evaluated. The model achieves an R2 value exceeding 0.99, with MAE and RMSE below 0.1℃. In addition, the monitoring system maintains a stable visualization frame rate of approximately 60 FPS and provides real-time information such as maximum temperature and safety status. Overall, this study offers a novel and safe solution for temperature monitoring during PBXs wire sawing and provides a new approach for enhancing the safety and intelligence of energetic materials machining processes.

Highlights

• A digital twin-driven temperature monitoring system for wire sawing is proposed.

• The surrogate model enables accurate and efficient temperature field prediction.

• Real-time temperature visualization is achieved with stable rendering performance.

• The approach improves safety and intelligence in machining energetic materials.