Identifying Carbon Footprint Reduction Opportunities through Energy Measurements in Sheet Metal Part Manufacturing

Shi, Chee Wai Patrick; Rugrungruang, Fatida; Yeo, Zhiquan; Gwee, Kenneth Hong Kiat; Ng, Ruisheng; Song, Bin

doi:10.1007/978-3-642-19692-8_67

Cited by 9 publications

(6 citation statements)

References 1 publication

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“…On the other hand, the power levels during the standby mode are significant, ranging from 1.4 kW to 5 kW for conventional hydraulic press brakes with a maximum capacity between 80 and 170 ton. Similar conclusions were drawn by Shi et al [179] for stamping processes. Ingarao et al [95] outlined the state of the art from a resource efficiency point of view for sheet metal forming technologies, covering the total life cycle starting from raw materials production up to recycling technologies.…”

Section: Forming Processessupporting

confidence: 90%

Towards energy and resource efficient manufacturing: A processes and systems approach

Duflou¹,

et al. 2012

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Section: Forming Processessupporting

confidence: 90%

Towards energy and resource efficient manufacturing: A processes and systems approach

Duflou¹,

et al. 2012

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“…The integrated design approach can improve material utilization by selectively using highstrength, thick materials in specific parts, reducing material engineering scrap rate through reasonably combining various steel plates, and realizing a raw material reduction in the hot stamping process. As a result, the integrated design approach significantly contributes to carbon emissions reduction due to less raw material consumption [3,73]. Furthermore, integrated part design can realize the integral stamping and one-time forming of parts, minimizing the number of hot stamping parts, stamping equipment, workflow, and tools, and reducing energy consumption in manufacturing.…”

Section: Part Designsmentioning

confidence: 99%

Low-Carbon-Emission Hot Stamping: A Review from the Perspectives of Steel Grade, Heating Process, and Part Design

Hou,

Liu,

et al. 2023

Automot. Innov.

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Hot stamping steels have become a crucial strategy for achieving lightweighting and enhancing crash safety in the automotive industry over the past two decades. However, the carbon emissions of the materials and their related stamping processes have been frequently overlooked. It is essential to consider these emissions during the design stage. Emerging materials and technologies in hot stamping pose challenges to the automotive industry's future development in carbon emission reduction. This review discusses the promising materials for future application and their special features, as well as the emerging manufacturing and part design processes that have extended the limit of application for new materials. Advanced heating processes and corresponding equipment have been proven to improve heating efficiency and control temperature uniformity. The material utilization and the overall performance of the components are improved by tailored blanks and an integrated part design approach. To achieve low-carbon-emission (LCE) hot stamping, it is necessary to systematically consider the steel grade, heating process, and part design, rather than solely focusing on reducing carbon emissions during the manufacturing process stage. This review aims to present the latest progress in steel grade, heating process, and part design of hot stamping in the automotive industry, providing solutions for LCE from a holistic perspective.

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“…Therefore, in the actual production and the experiment, thinning and thickening can be used to represent the possibility of fracture and wrinkling, respectively. These indices are calculated using Equations (9) and (10). An excessively large thinning rate of a sheet metal in a certain area means that the fracture trend is too large, whereas a disproportionately high thickening rate indicates a possible wrinkling phenomenon.…”

Section: Forming Quality Indicesmentioning

confidence: 99%

“…Process energy consumption models of hot stamping have been developed to qualify its energy consumption [9]. The associated carbon footprint is identified to analyze its environmental effects [10]. All the results show that oven curing accounts for a large amount of the products' energy consumption and environmental impact.…”

Section: Introductionmentioning

confidence: 99%

Energy-Economizing Optimization of Magnesium Alloy Hot Stamping Process

Gao

Wang

et al. 2020

Processes

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Reducing the mass of vehicles is an effective way to improve energy efficiency and mileage. Therefore, hot stamping is developed to manufacture lightweight materials used for vehicle production, such as magnesium and aluminum alloys. However, in comparison with traditional cold stamping, hot stamping is a high-energy-consumption process, because it requires heating sheet materials to a certain temperature before forming. Moreover, the process parameters of hot stamping considerably influence the product forming quality and energy consumption. In this work, the energy-economizing indices of hot stamping are established with multiobjective consideration of energy consumption and product forming quality to find a pathway by which to obtain optimal hot stamping process parameters. An energy consumption index is quantified by the developed models, and forming quality indices are calculated using a finite element model. Response surface models between the process parameters and energy-economizing indices are established by combining the Latin hypercube design and response surface methodology. The multiobjective problem is solved using a multiobjective genetic algorithm (NSGA-II) to obtain the Pareto frontier. ZK60 magnesium alloy hot stamping is applied as a case study to obtain an optimal combination of parameters, and compromise solutions are compared through stamping trials and numerical simulations. The obtained results may be used for guiding process optimization regarding energy saving and the method of manufacturing parameters selection.

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Identifying Carbon Footprint Reduction Opportunities through Energy Measurements in Sheet Metal Part Manufacturing

Cited by 9 publications

References 1 publication

Towards energy and resource efficient manufacturing: A processes and systems approach

Towards energy and resource efficient manufacturing: A processes and systems approach

Low-Carbon-Emission Hot Stamping: A Review from the Perspectives of Steel Grade, Heating Process, and Part Design

Energy-Economizing Optimization of Magnesium Alloy Hot Stamping Process

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