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Modular Design of Machine Tools to Facilitate Design for Disassembly and

Remanufacturing

Article · December 2014

DOI: 10.1016/j.procir.2014.06.085

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Procedia CIRP 15 (2014) 443 – 448

21st CIRP Conference on Life Cycle Engineering

Modular Design of Machine Tools to Facilitate Design for Disassembly and

Remanufacturing
PengjiaWanga, Yongxian Liua, S.K. Ongb, A.Y.C. Neeb,*
a
School of Mechanical Engineering & Automation, Northeastern University, Shenyang, Liaoning 110819, P.R. China
b
Mechanical Engineering Department, Faculty of Engineering, National University of Singapore, Engineering Drive 1, Singapore 117576, Singapore
* Corresponding author. Tel.: +65-67791459; fax: +65-65162892. E-mail address: mpeneeyc@nus.edu.sg

Abstract

Modular design as a modern design methodology can respond to market changes rapidly. At the same time, it is able to shorten product design
and manufacturing cycle, improve product quality and reliability, and facilitate product disassembly and remanufacturing. In order to achieve
machine tools modularization for remanufacturing, a modular design flow is proposed in this paper. Combined with the characteristics of the
various stages of product life cycle, disassembly criteria for modular design of machine tools for remanufacturing have been established from
the aspects of materials selection, remanufacturing process performance, use and maintenance performance, economic efficiency, and
functional and physical feasibility. Based on these criteria and a hierarchical clustering method, a similarity matrix for machine tools and
machine tool modules has been constructed. Finally, a machine tool HTC2550hs is used as an example to verify the validity of the proposed
method.
© 2014 The Authors.
Published by Published by Elsevier
Elsevier B.V. B.V.under CC BY-NC-ND license.
Open access
Selection
Selection and
and peer-review
peer-reviewunder
underresponsibility
responsibilityofofthe
theInternational
InternationalScientific
ScientificCommittee
Committeeofof
thethe
21st CIRP
21st Conference
CIRP onon
Conference Life Cycle
Life Cycle
Engineering in
Engineering in the
the person
personofofthe
theConference
ConferenceChair
ChairProf.
Prof.Terje
TerjeK.K.Lien.
Lien

Keywords: Modular Design; Machine Tools; Disassembly; Remanufacturing

1. Introduction
Remanufacturing engineering of mechanical and electrical
products has developed rapidly in recent years. By
implementing the remanufacturing strategy at the end of the
product lifecycle, the enterprise can reduce cost and improve
competitiveness largely. If the remanufacturing process is not
considered when a product is being designed, it will be
difficult to remanufacture the product at the end of its lifecycle,
as some of the components and parts could have been worn
badly, resulting in a product which cannot be remanufactured
[1]. Therefore, it is necessary to consider the remanufacturing
characteristics during the phase of product design, to facilitate
product reuse, upgrade and maintenance, and to make it easier
to disassemble and recover.
At present, there is yet to be a very perfect and precise
method which can solve the problems in remanufacturing.
Due to the trend of the diversification of customers' demands,
small product batches with high varieties, modular design has
been applied widely [2]. Modular design has many obvious
advantages, such as improving the design efficiency,
shortening the supply cycle, improving product quality and
reliability, good maintainability, etc. In order to coordinate the
design objectives, Gershenson et al [3] proposed the lifecycle-
oriented modular design method from three aspects of
components and parts attribute independence, process
independence and process similarity, Victor and Tseng [4]
have further specified the lifecycle driving factors of modular
design. In terms of modular indices determination, Xing et al
[5] proposed the concept of the product technology factor, and
established a mathematical model for products upgrade, Qian
and Zhang [6] introduced environmental awareness into the
modular analysis, and established the environmental influence
modular analysis model.
Thus, it can be seen that modular design as a key modern
design methodology not only has important theoretical and
practical values in improving the quality and comprehensive
performance of a product, shortening the design and

2212-8271 © 2014 Published by Elsevier B.V. Open access under CC BY-NC-ND license.
Selection and peer-review under responsibility of the International Scientific Committee of the 21st CIRP Conference on Life Cycle
Engineering in the person of the Conference Chair Prof. Terje K. Lien
doi:10.1016/j.procir.2014.06.085
444 Pengjia Wang et al. / Procedia CIRP 15 (2014) 443 – 448

manufacturing cycle, but also plays an important role at the
end of the product lifecycle. Thus, it can become an important
means to realize design for remanufacturing.
2. Modular design of machine tools for remanufacturing
dynamic parameters. If the range of parameter definition is too
large, it will increase resources and energy waste, such that the
parameters can improve the modularization degree on the
premise that the parameters can meet the customer
requirements.

Modular design is built on the basis of functional analysis Start

of a product with different functions or with the same function, Gather and analyze Requirement
statement
but different performances and specifications. This is achieved requirement

by dividing and designing a series of general function Decide series spectrum Spectrum
document
modules, and select and combine these modules to meet the and the main parameters

requirements of the customers. After module division, the Design Functional and
Module series design document physical criteria

Similarity measure
result should be evaluated from the technical, social and
economic aspects. If the evaluation index is not in conformity Module partition and Module
selection
with the demands, the module division result is irrational. In database
Remanufacturing

Irrational
many cases, if the module division is rational, reusing a The combination of Configuration design criteria
schemes
module or a part of an assembly at the end of the product modules

lifecycle can be realized. Otherwise, if the module division is

Product evaluation
irrational, a large amount of manpower and cost consumed
Rational
will be wasted since the components and parts may not be End
reusable. The use of modular design for remanufacturing is an
effective way to perform the configuration of the product Fig. 1. Modular design flow of machine tools for remanufacturing
structure at the conceptual design stage [7]. The design flow is
Good
illustrated in Figure 1. durability
Damage resistance
Clear wear condition
Not easily outdated
2.1. Customer remanufacturing requirements Easily identifiable
Multi-life cycle
Clear working life
Customer remanufacturing requirements are obtained by Easy to disassemble
Maintainability
surveying the customers, manufacturers and the
Disassembly stability
remanufacturing factories. It is necessary to carry out a Ease of Reusable
scientific classification, summarize the information and make disassembly and
Easy to reassemble
assembly
a conclusion. The development of the remanufacturing model Safe and reliable
depends on many factors, such as the impact on resources and Compatibility with Good stability
environment, customer requirements, the drive for higher the Ease of detection
profits, etc. The customer remanufacturing requirements of remanufacturing Easy to clean
processes
the machine tools are shown in Table 1.The requirements are
summarized by using the KJ (Kawakita Jiro) analytical
Fig. 2. Customer remanufacturing requirements summary
method [12]. The remanufacturing requirements of the
customer can be summarized as shown in Figure 2.
Table 1. The customer remanufacturing requirements
No. Name No. Name
2.2. Determination of the series spectrum and the main 1 Easy to disassemble 8 Maintainability
2 Disassembly stability 9 Easy to reassemble
parameters of the product 3 Damage resistance 10 Easy to clean
4 Clear wear condition 11 Ease of detection
The series spectrum and the main parameters of the product 5 Not easily outdated 12 Reusable
6 Safe and reliable 13 Easily identifiable
would need to be determined. Series spectrum is according to 7 Good stability 14 Clear working life
the analysis of the kindred production status at home and
abroad, planning the products types under the restriction of the
main parameter series and to present the relations between the 2.3. Module division and selection
basic product and variant product and the developing trends to
form a concise product variety factor diagram. The decision Module division can help recycle and reuse of the
on the size of the series spectrum is important. If the spectrum components and parts, and make the design process clearer
is too large, the product specifications will increase, the and more reliable. In recent years, the research of module
market adaptability will improve, and the module will have a division has attained some achievements. Tsai et al [8]
higher degree of common use; however the workload will be analyzed the module division method from the complexity of
heavier, the costs will increase, and the result may not be ideal the assembly process, Tseng and Chang [9] used the
in general. If the spectrum is too small, the above questions engineering parameters of connector such as the connection
may slide into reverse, the result may not be satisfactory type, connecting direction and disassembly tools as the
either. The parameters can be classified into three groups, module division criterion, Kimura et al [10] and Ishii et al [11]
namely, dimension parameters, motion parameters and studied the module division from the parts reuse and materials
 Pengjia Wang et al. / Procedia CIRP 15 (2014) 443 – 448
recycling, respectively. In the ideal world, modular product
should achieve the objectives of all the lifecycle stages.
However, product life cycle relates to multiple objectives, and
for different objectives, there can be different results, such that
the multiple objectives would need to be coordinated.
2.4. The combination of modules
It is necessary for the combination of modules to be
disassembled easily, avoid components damage, and reduce
disassembly time. Making better use of the existing modules
and enlarging the production quantity are the assurance to
determine the modularity benefits in product design. The
simpler way is to facilitate module searching and module
selection to establish the module library.
3. Module disassembly criteria for remanufacturing of
machine tools
This paper focuses on the customer remanufacturing
requirements, namely, durability, multi-life cycle, good
disassembly and assembly performance, compatibility with
remanufacturing processes, and the characteristics of the
various stages of product life cycle, namely, material selection,
use, recycle and remanufacturing, and proposes the module
disassembly criteria for remanufacturing of machine tools.
The similarity indices relate to the compatibility between two
parts. The compatibility aspects under consideration include
environmental impact, materials, useful life, maintainability,
recycling economy and efficiency, disassembly relationship
and functional and physical independence.
3.1. Material selection and configuration stage
This stage is the initial stage of the entire product lifecycle,
material selection should consider the environmental impact
of the materials, such as energy consumption, discharge, reuse,
etc. The ecological index reflects the environment effects of
the materials. The ecological index of some common materials
is shown in Table 2 (Eco-indicator99 method) [15].
Table 2. The ecological index of some materials
Materials Ecological index
Aluminium alloy 10.0-18.0
Copper alloy 60.0-85.0
Carbon steel 4.0-4.3
Cast iron 3.0-10.0
PVC 4.2-4.3
Criterion 1: The similarity criterion of environmental
impact of the materials. Components and parts with the same
or similar ecological index are grouped into the same module.
For components which have high impact on the environment,
remanufacturing is considered so that the impact on
environment and the energy consumption can be minimized.
For components which have little impact on the environment,
low-level handling is considered, such as landfill and material
recycling, to reduce any issues at the end of the product
lifecycle. Suppose Ime(i,j) is the similarity index of the
environmental impact between parts i and part j, the
445
computational formula is equation (1). In equation (1), mi and
mj represent the quality of parts i and j respectively, EIi and EIj
represent the ecological index of parts i and j respectively, 0<
Ime(i,j) İ1.
min( EI i mi , EI j m j )
I me (i, j ) (1)
max( EI i mi , EI j m j )
Criterion 2: The compatibility criterion of the material
remanufacturing process. Components and parts with the same
or compatible material are grouped into the same module.
Suppose Im(i,j) is the similarity index of the material
between parts i and part j, the computational formula is as
follows, where r represents the material similarity of parts i
and j, if the similarity is high, the value of r is larger.
­1
°
I m (i, j ) ® r , 0  r  1.
°0
¯
Suppose Ic(i,j) is the similarity index of the material
remanufacturing process between part i and part j, the
computational formula is as follows, r represents the material
remanufacturing process similarity of parts i and j, if the
compatibility is high, the value of r is larger.
­1
°
I c (i, j ) ® r , 0  r  1.
°0
¯
The material remanufacturing process compatibility is
equation (2), where ωm1 and ωm2 represent the weights of the
two similarity indices, ωm1+ωm2 = 1.
I cr (i, j ) Zm1I m (i, j )  Zm2 I c (i, j ) (2)
3.2. The usage stage
In the usage stage, the requirement of module division for
remanufacturing design mainly concentrates on the useful life
and maintainability.
Criterion 3: The criterion of useful life. The components
and parts with the same or similar useful life are grouped into
the same module. Suppose Il(i,j) is the similarity index of the
useful life between module i and module j, the computational
formula is equation (3), where Li and Lj represent the useful
life of module i and module j respectively.
min( Li , L j )
I l (i, j ) (3)
max( Li , L j )
Criterion 4: The criterion of maintainability. The
components and parts with the same or similar maintenance
requirements are grouped into the same module. The
maintainability is mainly shown in two aspects, namely, the
probability of relevant failure and the level of maintenance
resources shared.
Suppose Ia(i,j) is the similarity index of the maintainability
between module i and module j, the computational formula is:
I a (i, j ) Zmc I mc (i, j )  Zms I ms (i, j ) (4)
In equation (4), Imc(i,j) represents the level of maintenance
446 Pengjia Wang et al. / Procedia CIRP 15 (2014) 443 – 448

resources shared between parts i and part j. Ims(i,j) represents Table 3. The connection type and difficulty value
the probability of relevant failure between parts i and part j, No. Connection type Difficulty value
the relevant failure means when a component fails, it often 1 Welding 4.23
causes another related component to fail. ωmc and ωms 2 Bolted connection 4.04
represent the weights of the two different maintenance aspects, 3 Screw connection 4.04
ωmc+ωms = 1. 5 Light press fit 1.73
6 Clearance fit 0.96
7 Loose fit 0.38
3.3. The recycle and reuse stages 9 Limit 0.10

The discarded product can be recycled through reuse, Suppose Id(i,j) is the similarity index of the disassembly
material recycling and landfill. The effect of the relationship between part i and part j, the value of Id(i,j) is
environmental load and resource consumption in the various determined by the connection type. The connection type and
recycling strategies is shown in Figure 3. difficulty value is shown in Table 3.

Landfill 3.5. The functional and physical independence

Environmental load

Material

consumption
recycling

Resource
Meeting the functional and physical independence of
Parts
remanufacturing modules is the prerequisite and essence of modular partition.
Table 4 shows the definition of fuzzy relation˄substance,
energy, information and structure. The values are between 0
Reuse in product level
and 1, and the higher the value, the stronger is the interaction.
The life cycle
Top End
process Table 4. The definition of fuzzy relation

Fig. 3. The recycling strategies Fuzzy relation The interactivity value

Strong 1
Middle 0.6
Criterion 5: The criterion of economics. The components Weak 0.3
and parts with the same or similar recovery values are Nothing 0
grouped into the same module. The recovery value of a
component is determined by the material costs, manufacturing Criterion 7: The criterion of the functional and physical
processing costs and recycling costs. independence. The components and parts with the same or
Suppose mi and mj are the quality of parts i and part j, the similar functional and physical interactivity are grouped into
recovery value of part i and part j is (Cc+Cm-Ct)i and (Cc+Cm- the same module.
Ct)j respectively. Cc represents the material costs, Cm Suppose In(i,j) is the similarity index of functional and
represents the manufacturing processing costs and Ct stands physical independence between module i and module j, the
for the recycling costs. computational formula is equation (6), where ω1, ω2, ω3, ω4
Suppose Ie(i,j) is the similarity index of the recycling represent the weights of the substance, energy, information
efficiency between module i and module j, the computational and structure similarity coefficient respectively. Ips represents
formula is equation (5), where WRi and WRj represent the the corresponding similarity coefficient.
recovery value of part i and part j respectively. 4

min(WRi ,WR j ) I p (i, j ) ¦Z I i ps (i, j ) (6)

I e (i, j )
max(WRi ,WR j )
3.4. The remanufacturing processing stage
The criterion of remanufacturing performance design is
mainly reflected in two aspects, namely, disassembly criterion
and reassembly criterion [13]. Product non-destructive
disassembly is an important guarantee of the remanufacturing
process. It is necessary to analyze the disassemblability of
products, reduce the number of product parts, lower product
disassembly costs and shorten disassembly time, to solve all
the existing problems in disassembly during the design stage.
Criterion 6: The criterion of disassembly. The type of
connection between the components should facilitate
disassembly, and the number of interfaces should be reduced.
The disassembly complexity mainly depends on the
connection types and the corresponding values between the
components. Table 3 shows some of the connection types and
the difficulty values which are obtained from experiments.
(5) s 1
4. Module dividing method for the remanufacturing of
machine tools
A similarity matrix for the remanufacturing of machine tool
components is constructed through combining the criteria of
modular design for remanufacturing. The modules are
grouped using the hierarchical clustering method.
First, the relative importance of the criteria is analyzed
using the AHP (Analytic Hierarchy Process) method [14]. The
weights of the material environmental influence similarity,
material remanufacturing process compatibility, useful life,
maintainability, economic, disassembly, functional and
physical independence are calculated respectively.
An n-order similarity matrix R of machine tool components
is constructed. The similarity value between part i and part j is:
rij Z1I me (i, j )  Z2 I cr (i, j )  Z3 I l (i, j ) 
(7)
Z4 I a (i, j )  Z5 I d (i, j )  Z6 I e (i, j )  Z7 I p (i, j )
Next, the similarity matrix R is aggregated by using the
 Pengjia Wang et al. / Procedia CIRP 15 (2014) 443 – 448 447

hierarchical clustering method. For convenience, the part i

and part j are expressed as i and j, the distance of part i and
part j lij(i,j) is expressed as lij . Gp and Gq represent the
aggregation of the two parts respectively. Suppose they have
np and nq parts respectively. The distance of class Gp and Gq is
expressed as Lpq, Lpq=min έ lij ή , i ę Gp, j ę Gp,, i.e., the
minimum distance between the two classes is used as the
distance of class Gp and Gq.
The distance matrix L0 is obtained through the
transformation of matrix R. The computational formula is
equation (8).
Fig. 4. The CAD model of a CNC horizontal lathe
lij 1  rij , i, j {1, 2, , n} (8)
Next, the minimum off-diagonal elements are selected from
L0. Suppose lpq is the minimum element, Gp and Gq are Chunk Part1

aggregated to a new class, Gr=έGp , Gqή.The corresponding Spindle motor Part2

Cutting
row and line of Gp and Gq in L0 are removed; the new row function Spindle transmission Part3
and line that consists of the minimum distance of new class Gr
Spindle ease body Part4
and the non-aggregation class are added to form a new n-1-
order matrix L1. This operation is repeated until the n parts Z-direction motor Part5
aggregate into one class. In the aggregation process, the Z-direction lead screw Part6
Feeding
number of parts and the distance between the two classes function Z Saddle Part7
should be recorded, and the clustering chart is drawn.
Z-direction guide rail Part8

5. Application example X-direction motor Part9

CNC X-direction lead screw Part10

Feeding
A machine tool HTC2550hs is used to verify the validity of horizontal
Function X Sliding plate Part11
lathe
the proposed method. The CAD model of the horizontal lathe
X-direction guide rail Part12
is shown in Figure 4.The main function structure of the CNC
horizontal lathe is shown in Figure 5. Tailstock motor Part13

The weights, eigenvalue of maximum, and consistency of Tailstock screw Part14

Locate and
the matrix can be calculated using the AHP (Analytic support
Tailstock body Part15

Hierarchy Process). The weights of the material Tailstock guide rail Part16
environmental influence similarity, material remanufacturing Sleeve and Shaft Part17
process compatibility, useful life, maintainability, economic, Subsidiary
Tool post Part18
disassembly, functional and physical independence are: function

ω1=0.0240, ω2=0.0336, ω3=0.0535, ω4=0.0888, Support

Lathe bed Part19
function
ω5=0.1730, ω6=0.2511, ω7 =0.3760, respectively.
λmax=7.1797, Rc=0.0220, so the consistency of the matrix is Fig. 5. The main function structure diagram of a CNC horizontal lathe
acceptable.
The parts similarity can be calculated using formula (7). The distance matrix L0 can be obtained using formula (8).
The similarity matrix R is shown as follows: By using hierarchical clustering, the number of clustering part
ª1 0.67 0.89 0.63 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0º
and the distance between them can be obtained. The process
«
« 1 0.75 0.63 0.25 0 0 0 0.25 0 0 0 0.25 0 0 0 0 0 0 »» of the hierarchical clustering method is shown in Table 5. And
«
«
1 0.80 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0»
»
in Table 5, OB1~OB19 represent the original 19 parts, CL
1 0 0 0.17 0 0 0 0.17 0 0 0 0.20 0 0 0 0»
«
« 1 0.66 0.38 0.55 0.63 0.63 0 0 0.63 0.63 0 0 0 0 0»
represents the new aggregation classes. The clustering chart of
« »
« 1 0 0.55 0.63 0.63 0 0 0.63 0.63 0 0 0 0 0» a CNC horizontal lathe is shown in Figure 6.
« 1 0.25 0 0 0.63 0 0 0 0.17 0 0 0.23 0 »
« »
« 1 0 0 0 0.63 0 0 0 0.63 0 0 0»
« 5 6 9 10 13 14 8 12 16 15 17 7 11 1 3 4 2 18 19
1 0.66 0.38 0.55 0.63 0.63 0 0 0 0 0»
« »
R « 1 0 0.55 0.63 0.63 0 0 0 0 0» 0.11
« » 0.20 0.20
« 1 0.25 0 0 0.17 0 0 0.23 0 »
0.25
« 1 0 0 0 0.63 0 0 0» 0.34 0.34
« » 0.34 0.37
« 1 0.66 0.38 0.55 0 0 0» 0.37 0.37
« 1 0 0.55 0 0 0» 0.37 0.37
« »
« 1 0.25 0.8 0.17 0» 0.45
« 1 0.38 0 0»
« » 0.62
« 1 0 0»
« » 0.62
« 1 0»
«¬ 1 ¼» 0.75
0.77

Fig. 6. The clustering chart of a CNC horizontal lathe

 448 Pengjia Wang et al. / Procedia CIRP 15 (2014) 443 – 448

Table 5. The process of the hierarchical clustering method for enterprises to implement modular design and
New New clustering Minimum remanufacturing.
Parts in new class
Classes classes distance
CL18 OB1 OB3 {1,3} 0.11 Acknowledgements
CL17 OB15 B17 {15,17} 0.20
CL16 OB4 L18 {4,1,3} 0.20 This work is supported by the Research Funds of State
CL15 OB2 L16 {2,4,1,3} 0.25 Science and Technology Support Program (2012BAF10B11,
CL14 OB5 OB6 {5,6} 0.34 2012BAF12B08-04).
CL13 OB9 B10 {9,10} 0.34
CL12 OB13 B14 {13,14} 0.34 References
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Guidance X-direction guide rail,
Tailstock, guide rail.
Support Saddle, Sliding plate.
Tool magazine Tool post.
Lathe bed Lathe bed.

6. Summary

The module division of machine tools combined with the

characteristics of the various stages of product lifecycle can
meet the requirements for remanufacturing, the functional and
physical feasibilities, such as the disassembly conditions are
taken into account. In the CNC machine tool products
modular design process, module division is an important
aspect of modular design. This work is of great significance

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