Jan C. Aurich

An Approach to Life Cycle Oriented Technical Service Design

Abstract The importance of technical, i.e. product related services has significantly increased over the past years. Traditionally, technical services are provided during product usage. In light of the potential impact of technical services on the entire product life cycle, the application of life cycle engineering techniques to service design is suggested. Consequently, the presented research work aims at developing a service design process. Based on three main strategies for combining products with related services, a corresponding design process is proposed. It simultaneously considers the product, process and information dimensions of services.

Configuration of product‐service systems

Purpose – Traditionally, many manufacturers of cost intensive capital goods have largely focused on design, realization and distribution of high‐quality products. Meanwhile, their industrial customers increasingly expect to be provided with diverse services. These services predominantly aim at enhancing the functional and the economical performance of the underlying products. To systematically exploit the potential of services, an appropriate combination of products and services becomes crucial. For achieving desired benefits for both manufacturers and their industrial customers, product‐service systems (PSS) have to be configured systematically. This paper aims to address these issues.Design/methodology/approach – The presented approach considers customer, manufacturer and product life cycle specific aspects within the configuration of PSS. The paper presents a framework which comprises all activities necessary to conduct a systematic configuration of PSS. Throughout the paper, an elementary case study i...

Development of a Superabrasive Grinding Wheel With Defined Grain Structure Using Kinematic Simulation

Abstract This paper presents the concept of superabrasive electroplated grinding wheels based on defined grain structures. The aim is to improve process stability, minimize heat generation and achieve a high surface quality while preserving a high material removal rate. Based on geometrical models, different patterns of grit settings have been investigated by means of kinematic simulation. Applying the results of the simulation, a prototype grinding wheel with an optimized defined grain structure has been constructed. The performance potential of the prototype has been analyzed through experimental examinations.

3D Finite Element Modelling of Segmented Chip Formation

This paper presents a 3D coupled thermo-mechanical finite element model for the simulation of segmented chip formation in metal cutting. For modelling, a commercial finite element code is used. The generation of segmentation is achieved either by element erase with respect to damage or by modification of material flow stress data; both being coupled with continuous adaptive remeshing. A normalized Cockroft-Latham model is utilized as the damage criterion for element erase. Flow stress modification is achieved by using Rhims material model. Fundamental observations from the simulations are concluded and a guideline for further research is proposed.

Life Cycle Management of Industrial Product-Service Systems

Technical services aim at enhancing the economical and ecological performance of industrial products. To systematically exploit their potentials for both manufacturers and their industrial customers, products and services need to be integrated. Thereby, Life Cycle Management (LCM) provides a promising starting point. On the basis of corresponding methods, important fields of action, regarding the implementation of the resulting industrial Product-Service Systems (PSS) in the investment goods industry, can be identified with respect to customer-oriented PSS planning, integrated PSS development, knowledge based PSS control and life cycle-oriented process management. This article therefore introduces a novel concept for PSS-LCM and describes important elements thereof.

Modular design of technical product-service systems

Technical services (maintenance, upgrading, user training etc.) aim at enhancing the performance of investment goods. To systematically exploit their potentials the scope of traditional product engineering methodologies needs to be enlarged. A two step method will be introduced for this reason. It systematically builds up on the principle of modularization for realizing technical Product-Service Sys- tems, i.e. customer solutions comprising both physical (product) and non physi- cal (technical service) constituents. The method covers a process library for de- signing and manufacturing technical Product-Service Systems as well as a procedure for selecting, combining and adapting appropriate process modules.

Burr Formation and Surface Characteristics in Micro-End Milling of Titanium Alloys

Titanium base alloys are used for aircraft structures, turbine blades and medical implants. The surface of these parts can be functionalized by micro-structuring e.g. to get a more energy efficient turbine or to get a better biocompatibility for medical implants. Micro-end milling with end mills down to 300 μm is already efficient and reliable for microstructuring ductile materials. We developed and manufactured carbide micro end mills with a smallest diameter of 7 μm to improve the spectrum of functional structures.

Improvement of manufacturing processes with virtual reality-based CIP workshops

The Continuous Improvement Process (CIP) is a well-established method to improve manufacturing processes. A typical CIP workshop, carried out by a group of workers and engineers directly in production, often causes unwanted downtimes. Furthermore, improvements have to be realised without reliability testing. Virtual Reality (VR) provides a powerful means to support CIP workshops. This paper introduces the concept of a VR-based CIP workshop. User interfaces are proposed to integrate additional elements, e.g. findings of augmented reality, into VR. This allows meeting specific demands of different participants involved in a CIP workshop. The proposed concept is validated based on an industrial use case.

CBN-GRINDING WHEEL WITH A DEFINED GRAIN PATTERN – EXTENSIVE NUMERICAL AND EXPERIMENTAL STUDIES

This paper presents numerical and experimental investigations of a superabrasive electroplated grinding wheel with a defined CBN grain pattern and a standard superabrasive grinding wheel with a stochastic grain distribution. Concerning the numerical studies, kinematic simulations for different process parameters are performed. Thereby, the grinding wheel wear was numerically considered by decreasing the grain protrusion height by a numerical dressing process. The experimental studies concentrate on dry and wet (down and up) grinding operations of hardened heat-treated steel using material removal rates of up to /mms. Furthermore, the performance limits of the grinding wheel with a defined grain pattern are tested during wet up-grinding. Thereby, a good process behavior occurred up to a specific material removal rate of /mms. A main part of the experimental investigations are the macroscopic (radial wheel wear) and microscopic (grain wear, average grain protrusion height) wear studies of the grinding wheel with a defined grain pattern. As a promising progress, the numerical and experimental results of the grinding wheel with a defined grain pattern could be used to combine experimental process behavior with simulated chip parameters.

Manufacturing system design with virtual factory tools

During the analysis and design of manufacturing systems, companies are challenged by existing restrictions and the running production. To deal with these key issues, different virtual factory approaches and tools have been widely implemented in recent years. By employing modern approaches and tools, a manufacturing system can be adapted effectively. Virtual reality (VR), one of the most important approaches, has recently been applied to the scientific and the industrial fields. Recent studies of VR applications are mainly focusing on the design of products, but not manufacturing systems. This paper presents VR as an innovative and collaborative design platform for manufacturing systems, which enables a holistic use of virtual factory tools. Based on this platform, three applications were implemented, which are addressed at different levels of a manufacturing system. Furthermore, a noise simulation and a virtual machining tool were visualised in a cave automatic virtual environment (CAVE).