Efficiency of Manufacturing Processes: Energy and Ecological Perspectives (Sustainable Production, Life Cycle Engineering and Management)

This monograph presents a reliable methodology for characterising the energy and eco-efficiency of unit manufacturing processes. The Specific Energy Consumption, SEC, will be identified as the key indicator for the energy efficiency of unit processes. An empirical approach will be validated on different machine tools and manufacturing processes to depict the relationship between process parameters and energy consumptions. Statistical results and additional validation runs will corroborate the high level of accuracy in predicting the energy consumption. In relation to the eco-efficiency, the value and the associated environmental impacts of manufacturing processes will also be discussed. The interrelationship between process parameters, process value and the associated environmental impact will be integrated in the evaluation of eco-efficiency. The book concludes with a further investigation of the results in order to develop strategies for further efficiency improvement. The target audience primarily comprises researchers and experts in the field, but the book may also be beneficial for graduate students Foreword 7 Acknowledgments 9 Contents 11 1 Introduction 15 1.1 Problem Statement and Scope 15 1.2 Research Objective and Approach 16 References 18 2 Review on the State of the Research in Energy and Eco-efficiency of Manufacturing Processes 19 2.1 What Is Energy Efficiency 19 2.1.1 Thermodynamic Approach 20 2.1.2 Physical-Thermodynamic Approach 24 2.1.3 The Predictions of SEC 25 2.1.4 Energy Efficiency Practices in Manufacturing 29 2.2 What Is Eco-efficiency? 30 2.2.1 The General Definition of Eco-efficiency 30 2.2.2 Environmental Studies of Manufacturing Processes 31 2.2.3 LCCLCA Approach 33 2.3 Ensuing Need for Research 33 References 34 3 Methodology for Characterizing Energy and Eco-efficiency of Manufacturing Processes 37 3.1 Methodology of Energy Efficiency Evaluation for Unit Process 38 3.1.1 Empirical Modelling 38 3.1.2 Stage I: Methodology of Design of Experiments (DoE) 40 3.1.3 Stage II: Energy Metering and Monitoring System 44 3.1.4 Stage III: Statistical Analysis and Regression Methods 47 3.1.5 Stage IV: Validation Methods 50 3.1.6 Summary of Model Development 50 3.2 Methodology of Eco-efficiency Evaluation for Unit Process 50 3.2.1 Definition of Eco-efficiency Evaluation for Unit Process 50 3.2.2 The Value of a Unit Process 52 3.2.3 The Associated Environmental Impacts 53 3.2.4 The Interrelationship Within a Unit Process 56 3.3 Summary 56 References 57 4 Energy Efficiency Characterization of Manufacturing Processes 59 4.1 Energy Efficiency Characterization for Turning Processes 59 4.1.1 Background 59 4.1.2 Design of Experiments 60 4.1.3 Experiment Details 63 4.1.4 Regression Results 67 4.1.5 Model Validation 71 4.2 Energy Efficiency Characterization for Milling Processes 72 4.2.1 Background 72 4.2.2 Design of Experiments 73 4.2.3 Experiment Details 74 4.2.4 Regression Results for Dry Machining 76 4.2.5 Model Validation 79 4.2.6 Comparison Between Dry and Wet Machining 80 4.3 Energy Efficiency Characterization for Grinding Processes 81 4.3.1 Background 81 4.3.2 Design of Experiments 82 4.3.3 Experiment Details 87 4.3.4 Regression Results 87 4.3.5 Model Validation 90 4.4 Energy Efficiency Characterization for Injection Molding Processes 92 4.4.1 Background 92 4.4.2 Design of Experiments 93 4.4.3 Experiment Details 97 4.4.4 Regression Results 97 4.4.5 Model Validation 98 4.5 Energy Efficiency Characterization for Electrical Discharge Machining (EDM) Processes 102 4.5.1 Background 102 4.5.2 Design of Experiments 103 4.5.3 Experiment Details 105 4.5.4 Regression Results 107 4.5.5 Model Validation 109 4.6 Summary 109 References 111 5 Eco-efficiency of Manufacturing Processes 112 5.1 Eco-efficiency of Material Removal Processes 112 5.1.1 The Value of Material Removal Processes 112 5.1.2 The Associated Environmental Impact of Material Removal Processes 113 5.1.3 The Interrelationship Within the Material Removal Processes 113 5.2 Eco-efficiency of Injection Molding Processes 114 5.2.1 The Value of Injection Molding Processes 114 5.2.2 The Associated Environmental Impact of Injection Molding Processes 115 5.3 Eco-efficiency of Grinding Processes 116 5.3.1 The Value of Grinding Processes 116 5.3.2 The Associated Environmental Impact of Grinding Processes 117 5.3.3 The Interrelationship Within the Grinding Processes 121 5.4 Summary 124 References 124 6 Implementation Towards Improving Energy and Eco-efficiency of Manufacturing Processes 126 6.1 Investigation into Model Coefficients 127 6.1.1 Comparison Between Empirical Models and Exergy Framework 127 6.1.2 SEC Decomposition 128 6.1.3 Coefficients c0 and c1 132 6.2 Model Clustering for Metal Machining Processes 134 6.3 Implementation the Methodology of Energy Efficiency Evaluation in an Industrial Environment 136 6.3.1 Challenges in Industries 136 6.3.2 Modified Methodology for Characterizing Energy-Efficiency in Industries 137 6.3.3 Case Study: A Case of Sheet Extrusion Line 138 6.4 Improving Life Cycle Inventory (LCI) Database 145 6.5 Energy Efficiency Strategies for Manufacturing Processes 147 6.5.1 Energy Efficiency Strategies: An Operator’s Perspective 147 6.5.2 Energy Efficiency Strategies: A Machine Tool Builder’s Perspective 150 6.5.3 Energy Efficiency Strategies: A Designer’s Perspective 152 6.6 Summary 154 References 154 7 Conclusions 156 7.1 Concluding Remarks 156 7.2 Research Contributions 158 7.3 Recommendations for Future Works 158 Appendix 1 160 Appendix 2 161 Appendix 3 162 Appendix 4 180 Index 185 Front Matter....Pages i-xiv Introduction....Pages 1-4 Review on the State of the Research in Energy and Eco-efficiency of Manufacturing Processes....Pages 5-22 Methodology for Characterizing Energy and Eco-efficiency of Manufacturing Processes....Pages 23-44 Energy Efficiency Characterization of Manufacturing Processes....Pages 45-97 Eco-efficiency of Manufacturing Processes....Pages 99-112 Implementation Towards Improving Energy and Eco-efficiency of Manufacturing Processes....Pages 113-142 Conclusions....Pages 143-146 Back Matter....Pages 147-179