International Journal of Scientific Research and Engineering Development

High-precision robotic welding is critical in aerospace and space-grade manufacturing applications where geometric deviations can directly affect structural integrity and mission reliability. While automation frameworks improve execution consistency, predictive modeling of positional accuracy prior to deployment remains limited. This study presents a digital twin-based mathematical modeling and simulation framework for analyzing positional accuracy behavior in robotic welding systems. A kinematic model based on Denavit–Hartenberg (DH) parameters is developed, and joint-level error sources— including angular offsets, link deviations, backlash, and compliance effects—are systematically incorporated into the forward kinematic chain. A digital twin architecture enables controlled error injection and trajectory simulation for evaluating deviation growth under various operational scenarios. Sensitivity analysis is conducted to quantify the influence of small angular misalignments, initialization errors, and trajectory aggressiveness on end-effector positional drift. Results demonstrate that cumulative angular errors significantly amplify path deviation, while smoother trajectory planning mitigates dynamic instability. The proposed framework provides a predictive tool for pre-deployment validation, enabling risk-free optimization of robotic welding systems in high-reliability manufacturing environments.

Sangat Naik,"Digital Twin-Based Modeling and Sensitivity Analysis of Positional Accuracy in Robotic Welding Systems" International Journal of Scientific Research and Engineering Development, V9(1): Page(1968-1983) Jan-Feb 2026. ISSN: 2581-7175. www.ijsred.com. Published by Scientific and Academic Research Publishing.