Energy Efficient Manufacturing

Over the last several years, manufacturers have expressed increasing interest in reducing their energy consumption and have begun to search for opportunities to reduce their energy usage. In this book, the authors explore a variety of opportunities to reduce the energy footprint of manufacturing. These opportunities cover the entire spatial scale of the manufacturing enterprise: from unit process-oriented approaches to enterprise-level strategies. Each chapter examines some aspect of this spatial scale, and discusses and describes the opportunities that exist at that level. Case studies demonstrate how the opportunity may be acted on with practical guidance on how to respond to these opportunities.

Auteur

John W. Sutherland received his PhD from the University of Illinois at Urbana-Champaign and is a Professor and holds the Fehsenfeld Family Headship of Environmental and Ecological Engineering (EEE) at Purdue University. He is one of the world's leading authorities on the application of sustainability principles to design, manufacturing, and other industrial issues. He has published more than 300 papers in various journals and conference proceedings, authored several book chapters, and is co-author of the text "Statistical Quality Design and Control: Contemporary Concepts and Methods". He is a Fellow of the Society of Manufacturing Engineers, American Society of Mechanical Engineers, and CIRP (International Academy for Production Engineering). His honors and recognitions include the SME Outstanding Young Manufacturing Engineer Award, Presidential Early Career Award for Scientists and Engineers, SAE Ralph R. Teetor Award, SME Education Award, SAE International John Connor Environmental Award, and ASME William T. Ennor Manufacturing Technology Award.

David A. Dornfeld received his Ph.D. in Mechanical Engineering from UW-Madison in 1976 and was Will C. Hall Family Professor and Chair of Mechanical Engineering at University of California Berkeley. He led the Laboratory for Manufacturing and Sustainability (LMAS) and the Sustainable Manufacturing Partnership studying green/sustainable manufacturing; manufacturing processes; precision manufacturing; process monitoring and optimization. He published over 400 papers, authored three research monographs, contributed chapters to several books and had seven patents. He was a Member of the National Academy of Engineering (NAE), a Fellow of American Society of Mechanical Engineers (ASME), recipient of ASME/SME M. Eugene Merchant Manufacturing Medal, 2015, Ennor Award, 2010 and Blackall Machine Tool and Gage Award, 1986, Fellow of Society of Manufacturing Engineers (SME), recipient of 2004 SME Fredrick W. Taylor Research Medal, member Japan Society of Precision Engineering (JSPE) and recipient of 2005 JSPE Takagi Prize, Fellow of University of Tokyo Engineering and Fellow of CIRP (International Academy for Production Engineering). He passed away in March 2016.

Barbara S. Linke obtained her diploma and doctoral degree in Mechanical Engineering from the RWTH Aachen University, Germany. She worked at the Laboratory for Machine Tools and Production Engineering WZL from 2002 2010 on grinding technology and tooling engineering. From 2010 - 2012, Barbara was a research fellow at the University of California Berkeley. Since November 2012, Barbara Linke has been an assistant professor at the University of California Davis.

Contenu

1 Introduction to Energy Efficient Manufacturing 1
*Barbara S. Linke and John W. Sutherland*

1.1 Energy Use Implications 2

1.2 Drivers and Solutions for Energy Efficiency 3

References 9

2 Operation Planning & Monitoring 11
*Y.B. Guo*

2.1 Unit Manufacturing Processes 11

2.2 Life Cycle Inventory (LCI) of Unit Manufacturing Process 13

2.3 Energy Consumption in Unit Manufacturing Process 16

2.3.1 Basic Concepts of Energy, Power, and Work 16

2.3.2 Framework of Energy Consumption 17

2.4 Operation Plan Relevance to Energy Consumption 19

2.5 Energy Accounting in Unit Manufacturing Processes 20

2.6 Processing Energy in Unit Manufacturing Process 21

2.6.1 Cases of Processing Energy Modeling 21

2.6.1.1 Forging 21

2.6.1.2 Orthogonal Cutting 22

2.6.1.3 Grinding 24

2.6.1.4 Specific Energy vs. MRR 25

2.6.2 Energy Measurement 26

2.7 Energy Reduction Opportunities 26

2.7.1 Shortening Process Chain by Hard Machining 28

2.7.2 Substitution of Process Steps 28

2.7.3 Hybrid processes 29

2.7.4 Adaptation of Cooling and Flushing Strategies 29

2.7.5 Remanufacturing 30

References 30

3 Materials Processing 33
*Karl R. Haapala, Sundar V. Atre, Ravi Enneti, Ian C. Garretson and Hao Zhang*

3.1 Steel 34

3.1.1 Steelmaking Technology 35

3.2 Aluminum 36

3.2.1 Aluminum Alloying 37

3.2.2 History of Aluminum Processing 37

3.2.3 Aluminum in Commerce 38

3.2.4 Aluminum Processing 41

3.2.5 Bayer Process 42

3.2.6 Preparation of Carbon 44

3.2.7 Hall-Heroult Electrolytic Process 44

3.3 Titanium 45

3.3.1 Titanium Alloying 46

3.3.2 History of Titanium Processing 47

3.3.3 Titanium in Commerce 48

3.3.4 Titanium Processing Methods 49

3.3.5 Sulfate Process 50

3.3.6 Chloride Process 51

3.3.7 Hunter Process and Kroll Process 51

3.3.8 Remelting Processes 52

3.3.9 Emerging Titanium Processing Technologies 52

3.4 Polymers 54

3.4.1 Life Cycle Environmental and Cost Assessment 59

3.4.2 An Application of Polymer-Powder Processes 59

References 61

4 Energy Reduction in Manufacturing via Incremental Forming and Surface Microtexturing 65
*Jian Cao and Rajiv Malhotra*

4.1 Incremental Forming 66

4.1.1 Conventional Forming Processes 66

4.1.2 Energy Reduction via Incremental Forming 72

4.1.3 Challenges in Incremental Forming 75

4.1.3.1 Toolpath Planning for Enhanced Geometric Accuracy and Process Flexibility 76

4.1.3.2 Formability Prediction and Deformation Mechanics 85

4.1.3.3 Process Innovation and Materials Capability in DSIF 92

4.1.3.4 Future Challenges in Incremental Forming 95

4.2 Surface Microtexturing 97

4.2.1 Energy Based Applications of Surface Microtexturing 97

4.2.1.1 Microtexturing for Friction Reduction 97

4.2.1.2 Microtexturing Methods 101

4.2.1.3 Future Work in Microtexturing 114

4.3 Summary 115

4.4 Acknowledgement 116

References 116

5 An Analysis of Energy Consumption and Energy Efficiency in Material Removal Processes 123
*Tao Lu and I.S. Jawahir*

5.1 Overview 123

5.2 Plant and Workstation Levels 126

5.3 Operation Level 129

5.4 Process Optimization for Energy Consumption 134

5.4.1 Plant Level and Workstation Level 134

5.4.2 Operation Level 137

5.4.2.1 Turning Operation 137

5.4.2.2 Milling Operation 145

5.4.2.3 Drilling Operation 148

5.4.2.4 Grinding Operation 150

5.5 Conclusions 152

Reference 154 &l...