Hansgeorg Binz

How to Measure the Success Potential and the Degree of Innovation of Technical Ideas and Products

The evaluation of innovative ideas and products with regard to their success potential — in terms of market penetration — and the degree of innovation is a special challenge for research and development departments as well as for management. Therefore a new evaluation method was developed to quantitatively determine these two characteristic values. The basis of the new method is Quality Function Deployment, which was modified and expanded to consider aspects of novelty and enhanced customer and manufacturer benefit. The evaluation of the method in five pilot projects shows that the calculated evaluation figures are very well suited for decision making in the product development process.

Approach for recirculation of testing knowledge into product development supported by matrix-based methods

Testing methods are relevant to obtain information about product properties. This information must be transferred from testing departments and test benches to the design engineer. In testing departments, a lot of knowledge is generated, mainly about failures. This knowledge and experience is not used sufficiently during the development process. To support this recirculation of testing knowledge, an approach with matrix-based methods will be presented. Therefore, a Multiple Domain Matrix (MDM) was developed to store knowledge. The use of single matrices inside the MDM, and how to acquire the information for these matrices, will be discussed. The relevant measurement signals for interpreting failures detected by test benches are represented in particular detail. These can be used for automatically generated measurement signal diagrams. Computations of new dependencies inside the MDM support the use and distribution of testing knowledge. This use could also be supported by graphs to visualize the knowledge.

Numerical investigations on stress distribution and deformation of shaft-hub-connections manufactured by lateral extrusion

In this paper residual stresses and radial deformation of the hub of a shaft-hub-connection manufactured by lateral extrusion is examined within different methods. Beside FEA (finite-element analysis) the radial deformation of the external hub contour is determined by using a 3D coordinate measurement device. Residual stresses are examined also by FEA and by application of strain gauges to the external hub contour at the area of minimum and maximum hub thickness. A P3G polygon profile according to DIN 32711-1 [1] and DIN 3711-2 [2] showing a nominal diameter of 25 mm and a profile eccentricity of 1.12 mm is used as hub profile.

Increasing Effectiveness and Efficiency of Product Development - A Challenge for Design Methodologies and Knowledge Management

Information transfer and decision makingdecision making play dominant roles in the product development process. Information has to be retrieved, processed and outputted permanently. Thus, knowledge is generated and required to design this process effectively and efficiently, including making the right decisions. Therefore, supporting the product development process is a major task of design methodologies, knowledge managementknowledge management and tools. The future of Design Methodology has to be orientated around prospective product development. The present state of and challenges in product development are briefly described in this paper to realize future objectives for product development. Engineering Design Methodology’s general contribution and the Institute for Engineering Design and Industrial Design (IKTD)’s detailed schemes for achieving these objectives are depicted.

Consolidating Product and Process Information of Connections – A System-Theoretical Approach

The selection of the optimal connection is one of the most crucial parts in product development as it determines both, product properties and production processes. In multi-variant series production, functionality presumed, process cost is more and more in the focus of the selection. Designers face a big challenge in evaluating the feasible connections and surveying them holistically. Main challenge is the consideration of both, product and process related characteristics as they are documented according to different methodologies and in different sources. Therefore, a system-theoretical approach for consolidating product and process information is developed enabling designers effective designing and surveying the possible connections for given parts to be assembled. A case study evaluates impact on design time and connection quality.

Proof test of hybrid shrink fits with ceramic hub

Advanced ceramic machine components are required in many applications because of their specific material properties like high hardness, resistance to chemicals, corrosion and wear, low specific weight etc. The most suitable shaft-hub connection to ceramics is an interference fit assembly because it is free of geometrical notches and transmission of forces takes place in a large area. Such a shrink fit is rated for endurance strength when the stress intensity factor is below the specific value KI0 where no crack growth occurs. The total component suddenly fails, when the stress intensity factor exceeds the KIC value. The load to the press fit during the joining process, caused by the interference of the assembly, could be regulated by ambient conditions. In case of undetected material defects or microcracks in the ceramic and if the stress intensity is below KIC, the ceramic will not fail but a crack could grow. Thus, the joining process only seems to be a proof test. When the load during operation leads to a stress intensity that remains higher than KI0 the crack grows until the whole ceramic component fails. This effect was verified in tests at the Institute for Engineering Design and Industrial Design.