Thesis (PhD (Industrial Engineering))--University of Stellenbosch, 2010. / ENGLISH ABSTRACT: Information on the milling of Ti6Al4V is limited; with most studies concluding that it is not possible to obtain a significant increase in the material removal rate (Qw). Tool wear maps can be a diagnostic instrument for failure analysis. Cutting speed (vc), maximum un-deformed chip thickness (heMax) and the radial immersion percentage (ae/Ø %) are the key variables in understanding the milling of titanium alloys. The objective of this research study was to construct tool wear maps for the milling of Ti6Al4V. This will form the foundation of understanding the cutting demands on the tool, in order to analyse the main wear mechanisms. Remedial actions, which are developed by tool suppliers, can be considered and integrated via this understanding of the failure modes and related mechanisms. Firstly, experimental data from background studies, literature and industry on wear rates and wear mechanisms pertaining to the milling conditions was gathered to construct the tool wear map. Mathematical models describing the wear behaviour for these conditions were also investigated. Secondly, work piece failure maps have been superimposed onto the tool wear maps constructed to understand the global failure boundaries. Experimentation was carried out to validate the constructed maps. The tool wear map could then be used to discuss the observed effects and consider remedial actions. Cutting speed corresponds to the magnitude of the thermal load and heMax represents the mechanical load. The ae/Ø % defines the duration of the exposure to the thermal load at the edge of the cutting tool. This investigation has shown the following issues to be of importance when considering tool performance via the tool wear map approach: 1. The key to designing tool wear maps is to identify the most economic Scheduled Replacement Time (SRT) for the specific components. Knowing the correct SRT makes it possible to optimize the milling conditions so that the cutting tool wears gradually under the cutting conditions, and lasts longer than the economic SRT. 2. Increased vc will decrease tool life (TL). However, in low transverse rupture strength tools there may be a minimum vc below which mechanical overload may occur. Similarly, a local maximum TL (a sweet spot) may exist if there is a phase change in the work piece material. 3. Increased heMax will decrease TL. However, heMax must be kept below a maximum critical value to avoid mechanical overload, but above a minimum critical value to avoid work hardening. 4. Increased ae/Ø % will decrease TL. The best balance of high Qw and economic TL is found with ae/Ø between 30-40% for rough milling. In finish milling the radial cut is limited to 1 mm finishing stock of the work piece. This study revealed the following important factors when considering work piece failure in the milling of Ti6Al4V: 1. Increased vc will reduce the cutting resistance of the work piece and increase Qw. However, vc must be kept below a maximum critical value to avoid work piece material burn, but above a minimum critical value to avoid burring and poor surface finish, due to tool build-up and chip jamming. 2. Increased heMax will increase the cutting resistance of the work piece and increase Qw. The heMax must be kept below a maximum critical value to avoid poor surface finish, poor flatness and parallelism (due to work piece bending). Likewise, heMax must be kept above a minimum critical value to avoid work hardening and burring. The constructed tool wear maps are validated with experimental work. This research work identified safe zones to productively mill Ti6Al4V, while producing components with a sufficient surface integrity. / AFRIKAANSE OPSOMMING: Inligting rondom freeswerk van Ti6Al4V is beperk en volgens meeste studies is dit nie moontlik om ‗n wesenlike toename in die materiaal verwyderingstempo (Qw) te behaal nie. Snybeitel verwerings kaarte kan ‗n diagnostiese hulpmiddel wees tydens analisering van snybeitels. Snyspoed (vc), maksimum onvervormende spaanderdikte (heMax) en radiale snitdiepte persentasie (ae/Ø %) is die sleutel veranderlikes om die freeswerk van Ti6Al4V beter te kan verstaan. Die doel van die navorsingstudie was om snybeitel verweringskaarte vir die freeswerk van Ti6Al4V te bou. Die werk vorm ‗n fondasie om die eise van freeswerk op die snybeitel beter te verstaan. Sodoende kan die hoof verweringsmeganismes analiseer word. Regstellende aksies wat deur snybeitel vervaardigers ontwikkel is, was ondersoek en integreer met die huidige kennis rondom die falingstipe en verwerings meganismes. Aanvanklik was eksperimentele data van agtergrond studies, literatuur en industrie oor die verweringstempos en -meganismes rondom die freeswerk van Ti6Al4V versamel. Hiermee is verweringskaarte gebou. Wiskundige modelle wat die verwering kan beskryf was ook ondersoek. Daarna was werkstuk falingskaarte integreer met die ontwikkeling van die snybeitel verweringskaarte om sodoende die grense in geheel te verstaan. Eksperimentele werk was gedoen om die snybeitel verweringskaarte se uitleg te toets. Sodoende kon die snybeitel verweringskaarte gebruik word om die gedrag van die snybeitel te bespreek en regstellende aksies te ondersoek. Snyspoed (vc) stem ooreen met die grootte van die termiese lading en heMax verteenwoordig die grootte meganiese lading. Die ae/Ø % omskryf die tydperk van blootstelling aan die termiese lading op die snyrand. Die ondersoek het bewys dat die volgende faktore belangrik is wanneer snybeitel prestasie met die snybeitel verweringskaart evalueer word: 1. Die sleutel tot die ontwerp van snybeitel verweringskaarte is om die mees ekonomies beplande vervangingstyd (SRT) vir spesifieke komponente te identifiseer. Sodoende is dit moontlik om die frees toestande te optimaliseer, waaronder die snybeitels geleidelik sal verweer onder die eise en vir ‗n langer tydperk as die ekonomiese SRT sal kan sny. 2. Toename in vc sal snybeitelleeftyd (TL) laat afneem. Snybeitels met ‗n lae dwarsbreuksterkte, kan ‗n minimum vc hê waaronder meganiese oorlading plaasvind. Terselfdertyd, kan ‗n maksimum TL (‗n ―sweet spot‖) bestaan as daar ‗n fase verandering in die werkstuk materiaal plaasvind. 3. Toename in heMax sal TL laat afneem, maar moet laer as ‗n maksimum- en hoer as ‗n minimum kritiese waarde wees, om sodoende meganiese oorlading en werksverharding onderskeidelik te vermy. 4. Toename in ae/Ø % sal TL laat afneem. Die beste balans tussen TL en ae/Ø % is gevind met ae/Ø % tussen 30-40% vir growwe freeswerk. In afrondingsfreeswerk is die radiale snit beperk tot 1 mm van die oorblywende werkstuk. Die ondersoek het bewys dat die volgende faktore belangrik is wanneer werkstukfaling in ag geneem word met snybeitel verweringskaarte: 1. Toename in vc sal die werkstukweerstand geleidelik verminder en Qw laat toeneem. Ongelukkig is vc beperk tot ‗n maksimum kritiese waarde om werkstukfaling te voorkom weens ‗material burn‘. Die snyspoed moet ook hoër as ‗n kritiese waarde wees om werkstukklitsing en swak afronding weens spaander probleme te vermy. 2. Toename in heMax sal die werkstuk weerstand geleidelik vermeerder en Qw laat toeneem. Die heMax is beperk tot ‗n maksimum kritiese waarde om swak werkstuk afronding, weens die buiging van die werkstuk, te vermy. Terselfdertyd moet heMax hoër as ‗n kritiese waarde wees om werkstukverharding en -klitsing te voorkom. Die saamgestelde snybeitel verweringskaarte was bekragtig met eksperimentele werk. Die navorsingswerk het veiligheidsareas identifiseer om Ti6Al4V produktief te frees, sonder om die werkstukoppervlak krities te beïnvloed.

<p>Atlas Copco Tools & Assembly Systems (ACTA) is world leader in industrial tools and assembly systems for safety-critical joints. One of the products the company sells is fixtured nutrunners, mainly to the motor vehicle industry. The margins on these highly customized products have been decreasing – much depending on changes in the purchasing behavior of the automotive industry.</p><p>Traditionally, the marketing of the fixtured nutrunners has been concentrated to the parts of the product instead of the final product. Today, there is a belief within the organization that many of the sold customized products could be replaced by more standardized applications. There is also a wish to turn the focus of the market offer from the parts towards the final application. These beliefs and wishes resulted in this thesis, with the purpose to propose a new market offer to increase profitability and give more customer benefits.</p><p>To reach this purpose we started out with theoretical studies of several different areas. Among those was mass customization, a strategy that combines the benefits of mass production with those of customization. We also performed a prestudy at the headquarters of ACTA in Sickla and visited major customers in Sweden. Using our collected knowledge from the theoretical studies and the prestudy, we conducted an in-depth case study by interviewing customers and people working at ACTA, both in Sweden and in the USA, in order to analyze today’s situation. In the analysis, we found several problems with today’s offer. For instance, we found that similar products are solved with unique solutions, which has lead to poor cost control and has made it difficult for ACTA to assure the quality of the ordered products. A further problem is the poor sales support and the lack of traceability of sold systems, which reduces sales and leads to unnecessary special solutions. A problem linked to that is the difficulties in getting accurate and sufficient information from the customer, which leads to extra errors and a lot of extra work.</p><p>To solve these problems, we recommend ACTA to implement a mass customization strategy. Of course, not all of ACTA’s products can be mass customized, but to a large extent it should be possible. To implement a mass customization strategy, we argue that ACTA should take three measures, namely design standard products, modularize the products, and implement a computerized configuration tool. We also suggest that the implementation of the new market offer should be done stepwise. With the proposed new market offer, we believe that ACTA can increase profitability in the area of fixtured nutrunners without losing the flexibility of the products.</p>

Atlas Copco Tools &amp; Assembly Systems (ACTA) is world leader in industrial tools and assembly systems for safety-critical joints. One of the products the company sells is fixtured nutrunners, mainly to the motor vehicle industry. The margins on these highly customized products have been decreasing – much depending on changes in the purchasing behavior of the automotive industry. Traditionally, the marketing of the fixtured nutrunners has been concentrated to the parts of the product instead of the final product. Today, there is a belief within the organization that many of the sold customized products could be replaced by more standardized applications. There is also a wish to turn the focus of the market offer from the parts towards the final application. These beliefs and wishes resulted in this thesis, with the purpose to propose a new market offer to increase profitability and give more customer benefits. To reach this purpose we started out with theoretical studies of several different areas. Among those was mass customization, a strategy that combines the benefits of mass production with those of customization. We also performed a prestudy at the headquarters of ACTA in Sickla and visited major customers in Sweden. Using our collected knowledge from the theoretical studies and the prestudy, we conducted an in-depth case study by interviewing customers and people working at ACTA, both in Sweden and in the USA, in order to analyze today’s situation. In the analysis, we found several problems with today’s offer. For instance, we found that similar products are solved with unique solutions, which has lead to poor cost control and has made it difficult for ACTA to assure the quality of the ordered products. A further problem is the poor sales support and the lack of traceability of sold systems, which reduces sales and leads to unnecessary special solutions. A problem linked to that is the difficulties in getting accurate and sufficient information from the customer, which leads to extra errors and a lot of extra work. To solve these problems, we recommend ACTA to implement a mass customization strategy. Of course, not all of ACTA’s products can be mass customized, but to a large extent it should be possible. To implement a mass customization strategy, we argue that ACTA should take three measures, namely design standard products, modularize the products, and implement a computerized configuration tool. We also suggest that the implementation of the new market offer should be done stepwise. With the proposed new market offer, we believe that ACTA can increase profitability in the area of fixtured nutrunners without losing the flexibility of the products.

Two of the biggest issues facing large organizations today are knowledge transfer from the retiring Baby Boomers to their younger replacements, the Gamers, and the retention of those younger employees. Retirees are replaced by people 34 years old or younger who think, learn, believe, respond, and work differently further increasing the cultural gap that must be traversed in order to successfully transfer knowledge. This younger demographic is raised on technology and may not remember a time when there were no computers, video games, mobile devices, and the Internet. Large organizations aspiring to stay relevant must learn to take advantage of these unique traits. For organization that utilize repetitive work processes involving ruggedized handheld computing tools, both of these issues mentioned can be remediated through the adoption of modern technology. Some ruggedized handheld device manufacturers, however, have been hesitant to embrace consumer-implemented solutions such as the removal of all physical keys in order to incorporate touchscreen only input. Using Baby Boomer and Gamer-aged workers from a large transportation company experienced with ruggedized handheld devices, a time and error evaluation was performed to determine which input type is best by generation. This study found that moving from physical keyed devices to ruggedized handhelds with touchscreens only is a productive move for an industrial workforce but it’s the Boomers who stand to benefit from this change the most, not the Gamers. This study also identified near future requirements for the next iteration of ruggedized handheld devices based on the expectations of members of the current and future workforce. Results showed that participants from all generations selected a device that followed the touchscreen only model for data input. Experienced users from all generations preferred a smaller device with a large screen size. Lastly, Lean and Six Sigma were combined and their benefits explored in an effort of implementing manufacturing quality tools into a global, service-based, logistics organization. These tools and principles were used to improve the quality and timeliness of selecting and implementing a new ruggedized handheld device for the line-level workers on a global scale.