Efficiency of Manufacturing Processes: Energy and Ecological Perspectives PDF
Preview Efficiency of Manufacturing Processes: Energy and Ecological Perspectives
Sustainable Production, Life Cycle Engineering and Management Series Editors: Christoph Herrmann, Sami Kara Wen Li Efficiency of Manufacturing Processes Energy and Ecological Perspectives Sustainable Production, Life Cycle Engineering and Management Series editors Christoph Herrmann, Braunschweig, Germany Sami Kara, Sydney, Australia Modern production enables a high standard of living worldwide through products and services. Global responsibility requires a comprehensive integration of sustain- able development fostered by new paradigms, innovative technologies, methods and tools as well as business models. Minimizing material and energy usage, adapting material and energy flows to better fit natural process capacities, and changing con- sumption behaviour are important aspects of future production. A life cycle perspec- tive and an integrated economic, ecological and social evaluation are essential re- quirements in management and engineering. This series will focus on the issues and latest developments towards sustainability in production based on life cycle thinking. More information about this series at http://www.springer.com/series/10615 Wen Li Efficiency of Manufacturing Processes Energy and Ecological Perspectives 1 3 Wen Li Sustainable Manufacturing and Life Cycle Engineering University of New South Wales Sydney Australia Additional material to this book can be downloaded from http://extras.springer.com. ISSN 2194-0541 ISSN 2194-055X (electronic) Sustainable Production, Life Cycle Engineering and Management ISBN 978-3-319-17364-1 ISBN 978-3-319-17365-8 (eBook) DOI 10.1007/978-3-319-17365-8 Library of Congress Control Number: 2015940982 Springer Cham Heidelberg New York Dordrecht London © Springer International Publishing Switzerland 2015 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper Springer International Publishing AG Switzerland is part of Springer Science+Business Media (www.springer.com) Dedicated to my daughter Lynn Li, my wife Jie Zhu, and my parents —Wen Li Foreword Energy and eco-efficiency of manufacturing processes are of great interest to man- ufacturers, consumers, government and others. This is due to the soaring energy costs and the environmental impacts caused by high-energy consumption levels. However, the energy consumption of manufacturing processes and the associ- ated environmental impact has been historically overlooked. The unit process is the fundamental and dynamic element of any manufacturing system. Thus, it requires careful evaluation of its energy and eco-efficiency in order to derive fur- ther improvement measures. In this book, Dr. Li has developed a reliable methodology for characterizing energy and eco-efficiency of unit manufacturing processes. The Specific Energy Consumption, SEC, has been identified as the key indicator for the energy effi- ciency of unit processes. An empirical approach has been used to develop unit process energy consumption models based on SEC. Then these models have been validated on different machine tools and manufacturing processes to characterise the relationship between process parameters and energy consumptions. The tested cases cover a wide range of manufacturing processes including turning, milling, grinding, injection moulding and electrical discharge machining. All the derived SEC models agree with a universal form, where the Material Removal Rate (MRR) or throughput rate plays a decisive role in the model. The statistical results and additional validation runs have further proved the high accuracy of the derived models which is capable of predicting energy consumption with an accuracy of over 90 %. In order to characterise the eco-efficiency of manufacturing processes, Dr. Li also discussed the value and the associated environmental impacts of the pro- cesses. Besides the electricity energy consumption, other resource consump- tions such as tool and coolant have been taken into account. The interrelationship among process parameters, process value and the associated environmental impact has been integrated in the characterization of eco-efficiency. The results have been further investigated to develop strategies for improving the energy and eco-effi- ciency of manufacturing processes. vii viii Foreword In addition, Dr. Li has further decomposed the derived SEC models of manu- facturing processes in order to explore the mechanism of the model coefficients. A clustered model has been also generated for a rough estimation. In order to over- come the high efforts of empirical modelling, the methodology has been m odified for the implementation in an industrial environment. Moreover, the derived SEC models can be used for improving the quality of life cycle inventory (LCI) databases. As a result, it encourages progress in industry and research towards sustainability in manufacturing. Prof. Christoph Herrmann Prof. Sami Kara Technische Universität Braunschweig The University of New South Wales Acknowledgments The present book has been developed mainly in the context of my work as a researcher within the Sustainable Manufacturing and Life Cycle Engineering Research Group at The University of New South Wales (SMLCE@UNSW). First and foremost, I owe my sincerest gratitude to my supervisor and mentor, Prof. Sami Kara, who has supported me throughout my research with his patience and knowledge. It was always joyful and fruitful to discuss research questions as well as philosophical topics with him during all kinds of occasions. I greatly appreciate the excellent example he has provided as a successful academic. One simply could not wish for a better or friendlier supervisor. I would also offer my sincere gratitude to Prof. Dr.-Ing. Christoph Herrmann in Sustainable Manufacturing and Life Cycle Engineering Research Group at Technische Universität Braunschweig (TUBS). During my research visit to TUBS, I have been well supported and warmly welcomed by Prof. Herrmann and his research team. He has not only provided constructive suggestions for my research, but also integrated me as a member in his research team. I am indebted to many of my colleagues in the SMLCE@UNSW research group. Their encouragement and companionship has been very important to me. I would like to particularly acknowledge Dr. Seung Jin Kim and Dr. Supachai Vongbunyong for the friendship that I am keen to maintain. It was also a great pleasure to work with colleagues from the TUBS team, particularly Dr.-Ing. Sebastian Thiede, Dr.-Ing. André Zein, Dr.-Ing. Gerrit Posselt and Mr. Marius Winter, Dr.-to-be. Their enthusiasm, professionalism and knowledge for the research of sustainable manufacturing have deeply encouraged me for my research. Special thanks go to Ms Anne-Marie Schlake who heartened me to finish this book. I greatly appreciate Advanced Manufacturing CRC (AMCRC) for funding this research. Also, I have received great supports from the School of Mechanical and Manufacturing Engineering, UNSW, especially from Mr. Martyn Sherriff for assisting me with all the experiments. I would like to extend my gratitude to all the technicians from Sydney City TAFE who has also provided voluntary assistance for this research. ix x Acknowledgments Last but not least, I would like to attribute this book to my family for their love and encouragement. Most of all is for my loving, supportive and encourag- ing wife, Jie Zhu, whose faithful support is so appreciated. Equally important and appreciated is my daughter, Lynn Li, who is the true driving force for me to accomplish this book. Also, I thank my parents Rong Han and Fangze Li who have unconditionally supported me in all my pursuits. I would like to further thank Jie’s parents who have provided me with unending encouragement and support. Sydney Dr. Wen Li May 2014
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