Post on 19-Mar-2018
Sustainable Manufacturing
Energy efficiency of manufacturing systems and
manufacturing units
MAG Stiftungslehrstuhl für Fertigungstechnologien
Chinesisch-Deutsches Hochschulkolleg der Tongji-Universität
Prof. Dr. –Ing ZHANG Weimin
Outline
Background 1
High energy efficiency workshop 2
High energy efficiency machine tools 3
Advanced manufacturing process 4
Background
Sustainable development of Global, China & Tongji University
The core is Develop & Sustainable
To eliminate poverty and hunger;
To feed, nurture, house, educate
and employ the global population
To ensure peace, security
and freedom;
To preserve the Earth’s basic life
support systems.
Global sustainable development problem
213.46
258.68 291.45
324.94
361.73
152.51 184.95
209.30 232.02
252.46
123.00 151.27
172.11 189.41 205.67
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
2004 2006 2008 2010 2012
Total Energy Consumption (Bntce) Total industrial energy consumption (Bntce)Total manufacturing energy consumption Bntce)
• Sustainability of China
0.218
0.519
0.118 0.124
0.255
0.306
15094
7298 5869
3577
0
2000
4000
6000
8000
10000
12000
14000
16000
0.000
0.100
0.200
0.300
0.400
0.500
0.600
USA China Japan Germany World Asia
Energy consumption per unit GDP(TCE/k$) GDP(bn$)
Source:IMF2012
GDP USA(1) China(2) Japan(3) Germany(4)
Energy consumption per unit GDP rank USA(27) China(55) Japan(6) Germany(9)
World rank(2012)
The past 30 years, China's GDP grew by 15 times, while energy consumption increased by nearly four times, the main resource consumption and pollutant emissions per unit GDP is much higher than in developed countries
Source:IMF2012
The total energy consumption increase every year, but the growth rate decreased. Manufacturing share of energy consumption is about 56%
Energy consumption Source:NSBC
Annual Report from 1999
Science and technology innovation
En
erg
y s
avin
g
En
viro
nm
en
tal
Circ
ula
r
Eco
no
my
Re
so
urc
es
Renew
able
Ne
w E
ne
rgy
Re
so
urc
e
……
Society
Sustainable
Economic Sustainable
Ecology Sustainable
• Sustainability of China
Technological innovation is the basis, energy-saving technology, environmental technology etc as support.
Chinese government attaches great importance to sustainable development
Tongji University, “Institute of Environment for Sustainable Development”
Shandong University, “Research Center for Sustainable Manufacturing”
Dalian University of Technology, "Sustainable Design and Manufacturing Institute.“
Chongqing University, “Institute of Manufacturing Engineering”
Hefei University of Technology, “Green Design and Manufacturing Engineering”
……
• Universities actively participate
MOST, NSFC ,973 and 863 supports funded researcher for green manufacturing, remanufachturing, sustainable manufacturing, low-carbon manufacturing projects every year, which has made many achievements and partial results into applications.
• National research funds support
China and German manufacturing
• China has a rapid GDP growth, and manufacturing accounts for GDP than the major. China is a big but not power manufacturing country. The German economy is well developed, and it is a power manufacturing country.
• German trade close contacts, trade volume
• Mechanical and electrical products are an important component of trade between the two countries
Source: NSBC & MOFCOM
34.17 45%
10.22 13%
6.36 8%
4.52 6%
3.46 5%
17.63 23%
Germany import from china(bn $)
Mechanical and electricalproducts
Textiles and raw materials
Miscellaneous products,furniture, toys
Base metals and articles
Chemical products
Others
total 76.36 bn$
34.91 39%
28.02 31%
6.48 7%
6.07 7%
5.30 6%
8.59 10%
Germany export to China(bn $)
Mechanical and electricalproductsTransport equipment
Optical, watches, medicalequipmentChemical products
Base metals and articles
Others
total 89.36 bn$
59.21 49.92 68.05 76.40 69.21 76.362
55.79 55.72
74.26
92.74 91.92
89.36
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
2008 2009 2010 2011 2012 2013
China imports from German(bn $)
• Overview of China and German
70
166
2004年 2013年
China-German bilateral mechanical
equipment trade volume(bn RMB)
German machinery products mutually market their own merits. Overall, the German machinery products to China have obvious advantages.
Machine tools exporting to China are much larger than imports from China
High-precision, high-performance machine tools is the trend of the development in both countries.
17 16.4
3.8 4
2012 2013
Machine Export to China(bn EUR)
Machine Import from China(bn EUR)
Source: VDW & VDMA
Construction equipment and building material machinery, Mining equipment, Foundry machinery, Safes and strongroom installations
Machine tools, Agricultural machinery, Food processing and packaging machinery, Process plant and equipment, Fluid power equipment, Printing and paper equipment and supplies, Cleaning systems, Power Systems, Engines and systems.
Source: VDW
Source: VDW
• Machine & Mechanical equipment trade between China and German
• Superiority of China& German Manufacturing
• Main problems|面临的主要问题[1]
70% -80% of the
industrial energy
50% of national energy
costs
Improve
energy
efficiency
Demand for raw materials
increased by nearly 70%
(2001 to 2008)
30%-80% of
manufacturing costs
Improve
resource
efficiency
Energy|能源
Resource|资源
5% of industrial waste
generated by machinery
manufacturing industry
Rank 4th after chemical, oil,
coal and metal smelting
industry
More than 6 billion tons of
carbon emissions in 2008
The world's largest carbon
emissions producer
Discharge|废物排放
Reduce
carbon
emissio
ns
[1] National Bureau of statistics of China . China Statistical Yearbook 2005 ( M ). China Statistical Yearbook .2005.11.
Background of China manufacturing industry
Goal: Machine Tool with high productivity and high energy efficiency
Sustainable Manufacturing
Solution
China Development and Reform Commission: carbon taxes may begin in the "12 5" period .
• National medium-and long-term science and technology development plan (2006-2020) clearly
states that: the manufacture resource consumption, environmental load level must be reduced to
the ranks of the advanced international
• Executive meeting of the State Council of China announced on November 26, 2009: by 2020,
China's carbon dioxide emissions per unit of GDP decreased by 40% -45% compared to 2005.
Energy saving
Protection of basic energy
Limit excessive energy
Encourage saving energy
[1]. http://news.xinhuanet.com/fortune/2010-10/30/c_12719909_2.htm:节能·低碳·变革--国家能源局副局长吴吟解读“十二五”
规划能源领域三个关键词.
Low carbon
Low carbon concept
Low-carbon economy
Low-carbon society
Low-carbon technologies
Change
Energy use
Mode of production
Build a safe, stable,
economic, clean modern
energy industry system
Background
Chinesische Enviroment Energy Exchange
http://www.shanghai.gov.cn/shanghai/node2314/node2319/node12344/u26ai32789.html
http://www.cbeex.com.cn/ http://www.cneeex.com/ http://www.chinatcx.com.cn/tcxweb/
Tongji University have research a lot in sustainable development of university & country, and has gained rich achievements in sustainable manufacturing, green cars, green architecture etc.
• Sustainability of Tongji University
Green Energy
Smart Urban Factory
Smart Products
Green Manufacture
High efficiency Machine tools
Green Material
Advanced manufacturing process
Industry 4.0 smart Product is consist of Smart Urban Factory and Green Manufacture. And high efficiency workshop, high efficiency machine tools and advanced production process are important supports.
High efficiency workshop
Process and sustainable manufacturing
http://www.idnovo.com.cn/zhizao/2012/0531/article_12112.html
• National Science and Technology Major Project of Ministry of Science and Technology of China (Grant No. 2011 ZX04016-021)
Key technology and innovation platform of high speed / composite CNC machine tools • National Science and technology support program(Issue number: 2012BAF01B02)
Subject name: High speed and high precision CNC machine, tool key technology development and application of green manufacturing model。
• National Science and Technology Major Project of Ministry of Science and Technology of China (Grant No. 2012ZX04005031).
High speed / composite CNC machine tools and key technology innovation platform
• Current Projects
• Partners
Research interests: 研究方向:
• Lightweight design of high speed precision machine tools
高速精密机床的轻量化设计
• Energy saving technology of high speed precision CNC machine tool
高速精密数控机床的节能技术
• Green process technology for high speed precision CNC machine tool
高速精密数控机床绿色工艺技术
Classification of cutting machine tools : 切削加工中的机床分级研究:
单位功效碳足迹
噪声
粉尘浓度
油雾浓度
刺激性气味
2kg-CO /kg/cycle( )
3mg/m /cycle( )3mg/m /cycle( )
××
dB/ cycle( )
1
2
3
4
5
机床能效属性标识Re & En Label for Machine Tools
生产者名称 ___________________________
规 格 型 号 ___________________________
依据国家标准: GB xxxx.xxxx
好
中等
差
××
××
××
××
Different cutting method 不同的加工方法
Energy saving potential analysis
Classification of cutting machine tools
45,000kWh/year(1)
(165,000kWh/year(2))
(1)7.5kW bei 6000 h/a(PTW
TU Darmstadt, 2008)
(2)22kW bei 7500 h/a
(IWB TU Muenchen, in
Fertigung S.:30-32, 9-
2009) 1kWh equals
0.63kg CO2
10 X 10000km/year
(277g CO2/km)
4500€/year
In the huge energy consumption of machine tool, only 22% of the energy are used to cut off material!
Classification of cutting machine tools • Guide user to buy a more efficient machine tool • Promote machine tool company produce more
efficient machine tool • Support the government environmental policy • … …
单位功效碳足迹
噪声
粉尘浓度
油雾浓度
刺激性气味
2kg-CO /kg/cycle( )
3mg/m /cycle( )3mg/m /cycle( )
××
dB/ cycle( )
1
2
3
4
5
机床能效属性标识Re & En Label for Machine Tools
生产者名称 ___________________________
规 格 型 号 ___________________________
依据国家标准: GB xxxx.xxxx
好
中等
差
××
××
××
××
Energy & Resource label for machine tools
机床能效属性标识
• Parameters for
manufacturing
• Energy efficiency
• Resource efficiency
• Ecological impact
(Carbon footprint)
Classification for machine tools
High efficiency workshop
High efficiency Machine tools
Advanced manufacturing process
Carbon footprint (CFP) assessment system of
machining process
Energy efficiency evaluation of machine
tool (energy efficiency grading)
Hard turning (Replacing grinding)
• Focus on
CFP (Carbon Footprint) has historically been defined as "the total set of greenhouse gas (GHG) emissions caused by an organization, event, product or person[1].
More energy efficient and environmentally responsible: • Environmental Initiatives • Education & Awareness • Carbon Reduction • Energy & Resource Efficiency • Local Initiatives
[1]"What is a carbon footprint?". UK Carbon Trust. http://www.carbontrust.co.uk/ solutions/CarbonFootprinting/what_is_a_carbon_footprint. htm. Retrieved 2009-07-24.
6 main GHGs: CO2; CH4;N2O; HFCs;PFCs;SF6
Includes in the two levels : 两个层面的含义:
• Corporate Carbon Footprint 企业碳足迹
• Carbon footprint for a product 产品碳足迹
• 铝制品 • 糖厂
• 可乐生产 • 包装
• 运输 • 库存/冷藏
• 冷藏 • 回收易拉罐 • 垃圾处理/再利用
Carbon footprint for 1 can coca cola: 1罐可口可乐的“碳足迹”
-Company get the carbon emission information for production management 生产过程的碳排放管理
-Consumer make a significant impact on how people make choices about what (or even if) they buy 对消费者给予产品购买指导
Carbon Labeling(碳标签)
Procurement of raw materials
原材料生产
Product manufacturing
产品制造
Distribution & Retail
配送及零售
Consumption, use and
maintenance消费/使用
Disposal & Recycling
处理/回收再利用
Carbon Labeling
Carbon footprint such an important indictor?
traceability 可追溯
measurable可量化
universal 通用/广泛性
policy direction 政策趋势
economic benefit 经济效益
© Fraunhofer IWU
27
Fra
un
ho
fer
IWU
20
12
-04
_ P
z
Consumption of CO2 equivalents of a Golf VI *)
1: CO2 equivalents, incl. methane, laughing gas, cooling medium R132; incl. all materials and manufacturing processes; 150.000 km, incl. fuel supply
*) Prof. Heizmann, VW AG; presentation ICMC, 29.9.2010 Chemnitz
Need for action Operation phase Manufacturing phase
8 % fuels
0%
20%
40%
60%
80%
100%
20 % car manufacturing
70 % car operation
2 % recycling
CO21
∑ 27,4 t CO21
Climate protection
Products for Avoiding GHG
emissions Adapting to climate
change
Reduction for GHG emissions in
Production
Value chain
Advanced Technologies
Maximize economic benefits Energy & Resource Sustainable Development
• Evaluate indicator for greenhouse gas emissions due to energy consumption
• Measured by produced equivalent CO2e • More CO2e emission, larger carbon
footprint, and vice versa.
By Nicks J
Different GHGs (CO2, CH4, N2O, HFCs, PFCs, SF6 have different greenhouse effect . The Carbon dioxide equivalent value is used for CFP assessment by using GWP (Global Warming Potential) to calculate.
iieCO GWPME 2
ECO2e
GWPi
is for CO2e
is for Global Warming Potential
Mi is for gas weight
GHGs GWP (100 year) CO2 1
CH4 25
N2O 298
HFCS 124~14800
PFCS 7390~12200
SF6 22800
GHGs’ GWP
By IPCC
Mechanical processing of machine components is related to the , the carbon footprint of coolant, lubricant, cutting tools, metal chips etc.
CFP of Machining Process
ChipsCutting
toolCoolant
Lubricating oil
Electricity
…
1
m
nToolTotal Machine Coolant Lubricant Chip Others
i i i i i i i
m
C C C C C C C
𝐶𝑖𝑀𝑎𝑐ℎ𝑖𝑛𝑒 --CFP of electricity power consumption
𝐶𝑖Total --Total CFP
……
• CFP is defined as Carbon footprint per kilogram of a products.
Carbon footprint per kilogram(CFK)
Total
ii
i
CCFK
m im removal material Weight of product
Carbon Labeling
• Mitigation of climate change • To reduce greenhouse gas (Greenhouse
Gases, GHG) emissions • Promote low-carbon emission technologies
U.K. America Korea Canada
Japan France North America Chinese Taiwan
CFK is main index for
Carbon Labeling
单位功效碳足迹
噪声
粉尘浓度
油雾浓度
刺激性气味
2kg-CO /kg/cycle( )
3mg/m /cycle( )3mg/m /cycle( )
××
dB/ cycle( )
1
2
3
4
5
机床能效属性标识Re & En Label for Machine Tools
生产者名称 ___________________________
规 格 型 号 ___________________________
依据国家标准: GB xxxx.xxxx
好
中等
差
××
××
××
××
Source: Lange
材料利用率 加工方法 能源消耗
铸造
烧结
冷温压力加工
锻造加工
切削加工
Different Manufacturing → Different CFP
High efficiency workshop
low-carbon process
Manufacture process Research objectives:
•Clearly analyzing resource consumption in manufacturing process.
•Systematic evaluation of the low-carbon properties of manufacturing resources,
carbon footprint modeling
•The allocation of resources for the assessment of low-carbon manufacturing
process planning and optimization
Resource consumption
analysis
High efficiency and low carbon manufacturing resources evaluation and optimization
low-carbon evaluation
Manufacturing Resource Optimization for low-carbon and
efficient
Evaluation, control and optimization under constraint of resources and ecological environment during the production
process
Resource consumption analysis
Ecological constraints
Optimize the allocation of resources
Research content:
Analysis of resource consumption in
manufacturing process
Systematic evaluating low-carbon properties
of resources
Resources optimization
High efficiency & low-carbon manufacturing
low-carbon Grading
High efficiency & low carbon workshop
Carbon footprint (CFP) assessment system of machining process
Indicators for data collection 指标数据的采集 (1) indirect data directly after acquisition or acquisition through conversion and corresponding relationships; 间接数据直接采集或采集后通过相应关系进行换算 (2) according to the standard collection methods and requirements gathering, selection or direct experience; 按照国家标准的采集方法和要求进行采集,或者直接选用经验值 (3) using field observation on qualitative description. 采用现场观察进行定性描述
Composite index
Quantitative indicators
Resources Consumption
Waste disposal
Utilization
Qualitative indicators
Environmental management system
Auditing on energy-efficient production
Waste disposal system
Cost-based
indicators
Efficiency
indicators
Ecological
impact
Carbon emissions
Production process assessment
source: Daimler AG, PPA/GSU
In production process, the GHG emissions exist in each process, which includes direct discharge(DD), optional discharge(OD) and indirect discharge(ID).
Qualified products
Raw materials
Auxiliary materials
(lubricants, cutting
fluids...)
Energy (electricity,
heat...)
Others
Optimization technology
Input Disposals output
Output
Liquid wastes
Others
Dust
Carbon footprint
Other discharges
CH4
CO2
Process 1
Process 2
Process i
I1
I2
Ii
Process nIn
O1
O2
Oi
On
Transportation/
inventory Status 1
…
Status i
Production process for products
Production control
C1
Disposal Weights
C2
…
P1
P2
...
Pm
ωC1
ωC2
ωP1
ωP2
...
ωPm
…
Solid wastes
Gas C ω
…
Transportation/
inventory
Transportation/
inventory
ci
n
iiCC
1
Pi
m
iiPP
1
Ci (i=1,2,…,n) -- optional CO2e emissions induced from the use of materials/chemicals in an assessed process; ωCi --emission factor of the nth type of material. Pi --the discharge unrelated to carbon footprint(such as noise, dusts, etc.) ωPi --the emission factor of the mth type of material.
CFP Assessment Model for manufacturing system
Metal Cutting process (based on CFP)
1
m
nToolTotal Machine Coolant Lubricant Chip Others
i i i i i i i
m
C C C C C C C
Ci
machine = EFe´ (E
servomotor+ E
spindlemotor+E
coolingsystem+ E
compressor
+Ecoolantpump
+ Echipconveyor
+ EATC
+ Etoolmagazine
+ Estand-by
)
*coolantcprod cdisp coolant coolant water water water
update
{( ) ( ) ( )}coolant
i
tC EF EF V V EF V V
t
lubricant
spindlelub slidewaylubiC C C
{( ) }( 1)
prodtool
toolprod tooldisp tool re re
toolife re
tC EF EF m N C
t N
workpiece product density chip( )chip
iC V V EF
The total CO2e emissions of each product can be calculated out
Production process evaluation system
Resources
consumption
Ecological
influences
MaterialCutting
toolCoolant
Lubricating
oil Electricity
Pungent
odorOil mist Dust Noisy Security Others
Goal
Criterial
Machining Strategy
AlternativesMachine tool 1 Machine tool 2 Machine tool n. . .
CFKComprehensive index
system
• CFK is the main efficiency evaluation index of electrical energy , resource and and environmental emissions.
Carbon footprint per kilogram(CFK)
Total
ii
i
CCFK
m im removal material Weight of product
By AHP evaluation method
• A milling evaluation case
Workpiece & tool path
100±0.14
10
0±
0.1
4
37
±0
.1
42
28
48
50±0.1
6
5
17
.5
R6
Tool diameter 10mm with 30 °helix angle, XK714 CNC mill
Name Unit Value
electricity kg-CO2/kWh 0.5482
Coolant producing kg-CO2/L 2.85
Coolant processing kg-CO2/L 0.189
Dilution (water) kg-CO2/L 0.189
Spindle and guideway
lubricant producing kg-CO2/L 2.85
Spindle and guideway
lubricant processing kg-CO2/L 0.189
Tool producing kg-CO2/kg 24
Tool processing kg-CO2/kg 24
Regrinding kg-CO2/time 2.47
Chips processing kg-CO2/kg 2.47
CFP factor
Name Data Grade
Spindle & servo motor(g-CO2) 3.721
Auxiliary electricity(g-CO2) 75.895
Lubricant (g-CO2) 0.065
Chip (g-CO2) 10.99 ―
Tool (g-CO2) 12.361
Coolant (g-CO2) 1.747
Total CFP (g-CO2) 104.779
CFK(kg-CO2/kg) 0.606 3
CFK Noise Dust Mist Irritant gas Safety
CFK 1 5 3 3 3 2
Noise 1/5 1 1/3 1/3 1/3 1/4
Dust 1/3 3 1 1 1 1/3
Mist 1/3 3 1 1 1 1/3
Irritant gas 1/3 3 1 1 1 1/3
Safety 1/2 4 3 3 3 1
Carbon emissions
Manufacturing resources configuration judge matrix
133342/1
3/111133/1
3/111133/1
3/111133/1
4/12/12/12/115/1
233351
A
TW )262.0,112.0,112.0,112.0,058.0,343.0(
CFK weight 2.079
Grade 1 2 3 4 5
Degree Very
slight
sligh
t
Med
ium
Seve
re
Very
Severe
Weight 0-1 1-2 2-3 3-4 4-5
Weight calculating
Resource environment property Grading
High efficiency Machine tools
Research objectives:
•Machine tool energy consumption monitoring platform •Efficiency evaluation sample design, evaluation methods and energy efficiency rating. •High Efficient manufacturing process optimization •High Efficient machine tool design for high performance
Research content:
Energy efficiency evaluation of machine tool (energy efficiency grading)
Environment Evlauation
Dust
Oil mist
Irritant gases
Noise
Po
we
r Effice
ncy
单位功效碳足迹
噪声
粉尘浓度
油雾浓度
刺激性气味
2kg-CO /kg/cycle( )
3mg/m /cycle( )3mg/m /cycle( )
0.602
76
0.86
2.73
3
dB/ cycle( )
1
2
3
4
5
机床资源环境属性标识Re & En Label for Machine Tools
生产者名称 日本大隈株式会社 社
规 格 型号 1 MB-46VA立式加工中心 1
依据国家标准: GB xxxx.xxxx
好
中等
差
3级
Energy, Raw material(Semi -
finished products),Auxiliary
materials(coolant, Lubricants)
Solid, liquid gas Waste
Environmental Factors
Air heat exchange
Machine tool structural modeling
Evaluation BoundaryEvaluation objective Process Test Workpiece
Signal acquisition and analysisResults Evaluation
Source: Prof. Abele, Prof. Heisel, Prof. Verl
CFK Evaluation
Difficulties:
•CFK test Workpiece •The appropriate cutting parameters
单位功效碳足迹
噪声
粉尘浓度
油雾浓度
刺激性气味
2kg-CO /kg/cycle( )
3mg/m /cycle( )3mg/m /cycle( )
××
dB/ cycle( )
1
2
3
4
5
机床能效属性标识Re & En Label for Machine Tools
生产者名称 ___________________________
规 格 型 号 ___________________________
依据国家标准: GB xxxx.xxxx
好
中等
差
××
××
××
××
Power efficiency
Process parametersoptimization
Machine tools innovation
Test Workpiece
Reasonable design,
suitable for machine tool
Rough/finishingprocess,
combination of experimental parameters
Weights of each process
Energy comsumption
Dimension, surface quality
Process MeasureEnergy
efficiency
Noise,Dust,Oil mist etc
CNC lathe energy efficiency evaluation
Power efficiency : The value of power for material removal divided by the total machine tool power
High efficiency Machine tools
Source:Nancy Diaz
CNC lathe energy efficiency evaluation
•Usually, with restrict parameters, the cutting power is proportion to the MRR(material removal rate), but the energy is not. •With different cutting parameters, like rough and finish process, the ratio of power and MRR is different.
Characteristics of rough and finish lathe machining • Within a certain range: cutting power efficiency
increases with increasing of f, ap and Vc. • f, ap, Vc are limited to the machine rigidity, processing
quality, tools and other factors, so they can not be increased without limit.
• Evaluation of the energy efficiency of the lathe cutting power should be limited to the scope of the process parameters. Evaluate energy efficiency respectively
during roughing or finishing process.
Rough ,finish or both? The exact process parameters? The weight of each process ?
Source:Nancy Diaz
Lathe cutting example SKF3 steel pipe with 140mm OD 80ID
• Rough:Spindle vary at 40% to70%,(Ra<6.3)
• Set ap2.25~0.275; f 0.3375~0.4125; Vc373.5~415
No ap(mm) f(mm/r) vc(m/min) Total power(w) Cutting power(w) efficiency
1 2.25 0.3375 373.5 14550 8703.377 59.82%
2 2.25 0.375 415 17250 10603.78 61.47%
3 2.25 0.4125 456.5 20150 12600.15 62.53%
4 2.5 0.3375 415 17300 10690.12 61.79%
5 2.5 0.375 456.5 20350 12831.24 63.05%
6 2.5 0.4125 373.5 18700 11623.65 62.16%
7 2.75 0.3375 456.5 20450 12297.7 60.14%
8 2.75 0.375 373.5 18700 12199.56 65.24%
9 2.75 0.4125 415 22200 14237.24 64.13% • Finish (Ra<3.2)
• set ap0.3~0.5; f 0.1~0.3; Vc 370~475
ap(mm) f(mm/r) vc(m/min) Total power(w) Cutting power(w) efficiency
1 0.3 0.1 370 2540 778.75441 30.66%
2 0.3 0.2 475 3580 1426.852 39.86%
3 0.3 0.3 555 4740 2204.4604 46.51%
4 0.4 0.1 475 3270 1264.8571 38.68%
5 0.4 0.2 555 4550 2109.7439 46.37%
6 0.4 0.3 370 4150 1713.3343 41.29%
7 0.5 0.1 555 4160 1848.9585 44.45%
8 0.5 0.2 370 3860 1226.267 31.77%
9 0.5 0.3 475 5420 2534.5056 46.76%
Rough efficiency: 62.26% ; Finish efficiency : 40.70%; Set weight of rough and finish is 0.8 and 0.2,then the overall efficiency is57.95%
Energy efficiency test sample
Workpiece machining→ Power status → Efficiency of power → Continuous testing → efficiency of energy
As shown in this test sample, the rough process parameter ap=2.5,Vc=415,f=0.375, finish process parameter ap=0.4, Vc=475, f=0.2, efficiency of energy :37.8%
Grade 1 2 3 4 5
Degree >50
%
40~5
0%
30~4
0%
20~3
0%
<50
%
Resource environment property Grading
机床能效
机床额定功率
37.8%
30Kw
1
2
3
4
5
机床能效属性标识Re & En Label for Machine Tools
生产者名称 ___________________________
规 格 型 号 ___________________________
依据国家标准: GB xxxx.xxxx
好
中等
差
3级
Research objectives:
• Comparing with traditional lathe, research differences of hard-turning lathe process parameters.
• Optimize process parameters for high performance machining. • Comparing with the grinder, hard-turning energy efficiency.
Advanced manufacturing process
Hard turning (Replacing grinding)
Research content:
Optimized process parameters
hard-turning energy efficiency
Specimens
Pipe,pipe with one slot,pipe
with 4 slots.
Orthogonal test parameters(Finish cutting)
Weights of each process
Tool wear
Dimension, surface quality
Cutting MeasureComprehensive evaluation
Energy consumption
High rigidity lathe
CY-CTC4050 high stiffness slant bed CNC lathe has excellent hard cutting performance, it can machine HRC 62 hardness workpiece. Closed loop control, the maximum spindle speed 4000 rpm, with high rigidity, high accuracy, high dynamic response, and efficient.
Conclusions •Comparing with traditional lathe, the hard-turning machine has a good rigidity, can cut HRC56~62 hardness workpiece.
•Using appropriate process parameters , it can gain rather well dimension precision, the roughness can reach Ra<0.2.
•No burn phenomenon
•Energy consumption lower than same accuracy grinding machine
•Slot benefit chip breakage, the surface quality is better than no slot.
•Smaller feedrate helps improve surface quality.
Ra=0.4 no slot Vc=240, f=0.15, ap=0.3
Ra=0.35 one slot Vc=120, f=0.15, ap=0.2
Ra=0.35 one slot Vc=120, f=0.15, ap=0.2
Summary and Outlook
单位功效碳足迹
噪声
粉尘浓度
油雾浓度
刺激性气味
××
1
2
3
4
5
机械工艺碳排放属性标识Carbon Emissions Label for
Machining Product
生产者名称 ___________________________
规 格 型 号 ___________________________
依据国家标准: GB xxxx. xxxx
碳排放影响小
××
××
××
××
碳排放影响大
1
工艺过程产生
碳足迹
碳足迹量化
(CFP)
单位功效碳足迹
(CFK)
碳足迹分级评价
(评价碳效益)
...
CFK
单位:kgCO2/kg
加工工件
Carbon Footprint
China