Unit process energy consumption models for material removal processes

Economical, environmental and legislative drivers have recently raised the awareness of energy consumption and the associated environmental impact of manufacturing processes. A reliable prediction of unit process energy consumption will enable industry to develop potential energy saving strategies during product design and process planning stages. This paper presents an empirical model to characterize the relationship between energy consumption and process variables for material removal processes. The methodology has been tested and validated on a number of turning and milling machine tools. The model presented predicts the energy consumption of manufacturing processes with an accuracy of more than 90%.     

Carbon emissions and CES™ in manufacturing

The manufacturing of a product is connected directly to the amount of carbon emitted in producing electrical energy for that manufacturing process. A new, simple Carbon Emission Signature, CES™, is proposed. Knowing the CES for a power grid and the energy needed to make a part, the carbon emitted can be found. Examples of single point turning and open die forging are given. Knowing the total carbon emitted for a product, a manufacturer can place a Green House Gas (GHG) label on each product. A customer can then see the amount of Green House Gas emitted in making the product.     

Energy oriented simulation of manufacturing systems – Concept and application

Energy efficiency has become a key concern in industry due to the increased energy costs and the associated environmental impacts. Besides considering single processes/machines, the perspective on process chains and factories as a whole bears further potentials for improvement. In this context, dynamic interactions of different processes as well as auxiliary equipments (e.g. compressed air generation) need to be taken into account when planning and controlling manufacturing systems. This paper presents an innovative energy oriented simulation model for planning of manufacturing systems. A number of industry cases are used to demonstrate the potentials and applicability of the proposed methodology.     

PLM支持下的虚拟制造技术及其应用研究

本文总结阐述了虚拟制造的概念、范畴、关键技术、应用意义等内容,分析归纳了我公司业务流程的现状及其面临的挑战,据此提出了我公司业务对虚拟制造技术的需求以及相应的新流程,最后给出了达索系统和西门子PLM针对我公司业务需要制定的技术解决方案,希望对后续项目的开展起到积极的帮助作用。     

敏捷制造环境下制造单元的控制研究

敏捷制造环境下的制造单元是由分布的制造资源组成。本文通过敏捷制造单元组织结构和特性研究,设计了基于智能代理技术的网络资源搜索和面向对象信息集成的敏捷制造单元组建流程,提出了一种新的单元控制结构模型。     

基于IE的模具制造

概述了IE（工业工程）的方法，并针对在模具生产中的运用，从提高效率，保证质量，降低成本等方面展开讨论。     

Minimising Embodied Product Energy to support energy efficient manufacturing

Green sources of power generation and efficient management of energy demand are among the greatest challenges facing manufacturing businesses. A significant proportion of energy used in manufacturing is currently generated through fossil fuels. Therefore in the foreseeable future, the rationalisation of energy consumption still provides the greatest opportunity for the reduction of greenhouse gases. A novel approach to energy efficient manufacturing is proposed through modelling the detailed breakdown of energy required to produce a single product. This approach provides greater transparency on energy inefficiencies throughout a manufacturing system and enables a 20-50% reduction of energy consumption through combined improvements in production and product design.     

我国模具工业的现状与发展

在综合各种献资料的基础上,简要地阐述和分析了我国模具工业的现状与发展趋势。为模具行业的企业改造和行业调整还提出了一些新的思路。     

模具绿色制造过程探讨

介绍了当前模具绿色制造的基本概念和五个主要阶段中需要注意的一些技术性问题，最后对今后整个社会的绿色制造概念推广提出了一些建设性的建议。     

人工智能在机械制造及其自动化中的应用分析

人工智能是行业发展趋势,本文通过分析人工智能在机械制造及其自动化中应用,旨在提高人工智能在行业发展过程的应用深度,为行业发展提供切实可行路径.     

面向离散制造业的MES单元控制器研究

离散制造业具有产品结构、工艺流程和组织结构复杂、生产周期较长、零部件种类繁多等特点.RFID技术为制造执行系统的数据采集功能提供了一种高效、可靠的实时数据采集技术.以某公司汽油机生产线MES项目为背景,对基于RFID的MES单元控制器进行了研究,提出一种MES单元控制器设计,从软件角度研究了其体系结构和不同功能模块.该单元控制器提供了在制品识别、电子看板指导、物料比对等功能,其网络化监控与管理实效明显.     

基于Web的模具制造工艺的协同规划

针对模具制造特点，从面向生产管理的角度，提出了基于Web的模具制造工艺协同规划方法，探讨了实现这一方法的相关技术，并用Java语言开发了基于Web的模具CAPP原型系统。     

Carbon footprint as environmental performance indicator for the manufacturing industry

With the current focus on our climate change impacts, the embodied CO₂ emission or “Carbon footprint” is often used as an environmental performance indicator for our products or production activities. The ability of carbon footprint to represent other types of impact like human toxicity, and hence the overall environmental impact is investigated based on life cycle assessments of several materials of major relevance to manufacturing industries. The dependence of the carbon footprint on the assumed scenarios for generation of thermal and electrical energy in the life cycle of the materials is analyzed, and the appropriateness of carbon footprint as an overall indicator of the environmental performance is discussed.     

Manufacturing processes modelling for environmental impact assessment

Pursuing clean production and the manufacturing of green products are very beneficial in the alleviation of environmental burdens. In order to reap such benefits, a life-cycle analysis should be applied for all products and processes. Thus, establishing an assessment model for manufacturing processes in terms of environmental impact is necessary for quantitative evaluation of product design. In this paper, an assessment methodology is developed on the basis of the ‘material balance’ of a process and the relationship amongst different processes. As a result, the amount of solid waste generated, the energy consumed, the waste-water incurred as well as the level of noise are obtained. A case study of the production of a toy train with twelve scenarios is performed to illustrate and examine the assessment model, this study showing that the number of components, the selection of materials and processes, and recyclability are the essential factors to determine whether the products are environmentally-oriented.     

Additive manufacturing of metal components with the ARBURG plastic freeforming process

Using the ARBURG freeformer in the metal injection molding (MIM) process chain instead of an injection molding machine for molding the parts constitutes a new approach for the additive production of sintered metal components. Its main benefits are toolless manufacturing and using the conventional MIM feedstock. This paper presents this kind of approach with a carbonyl iron feedstock. The investigation includes the determination of the influences of the relevant printing process parameters on the mechanical properties of the sintered parts and the comparison with MIM. Experimental results are discussed, including an analysis of microsections, density, tensile strength R_m and shrinkage.     

Design and management of manufacturing systems for production quality

Manufacturing companies are continuously facing the challenge of operating their manufacturing processes and systems in order to deliver the required production rates of high quality products, while minimizing the use of resources. Production quality is proposed in this paper as a new paradigm aiming at going beyond traditional six-sigma approaches. This new paradigm is extremely relevant in technology intensive and emerging strategic manufacturing sectors, such as aeronautics, automotive, energy, medical technology, micro-manufacturing, electronics and mechatronics. Traditional six-sigma techniques show strong limitations in highly changeable production contexts, characterized by small batch productions, customized, or even one-of-a-kind products, and in-line product inspections. Innovative and integrated quality, production logistics and maintenance design, management and control methods as well as advanced technological enablers have a key role to achieve the overall production quality goal. This paper revises problems, methods and tools to support this paradigm and highlights the main challenges and opportunities for manufacturing industries in this context.     

On-machine and in-process surface metrology for precision manufacturing

On-machine and in-process surface metrology are important for quality control in manufacturing of precision surfaces. The classifications, requirements and tasks of on-machine and in-process surface metrology are addressed. The state-of-the-art on-machine and in-process measurement systems and sensor technologies are presented. Error separation algorithms for removing machine tool errors, which is specially required in on-machine and in-process surface metrology, are overviewed, followed by a discussion on calibration and traceability. Advanced techniques on sampling strategies, measurement systems-machine tools interface, data flow and analysis as well as feedbacks for compensation manufacturing are then demonstrated. Future challenges and developing trends are also discussed.     

A modelling framework for comparing the environmental and economic performance of WAAM-based integrated manufacturing and machining

Additive Manufacturing has proved to be suitable for supporting or even replacing traditional manufacturing approaches in some industrial contexts. Among the various processes that can be used to produce metal parts, Wire Arc Additive Manufacturing (WAAM) is known to be an economically convenient, welding-based direct energy deposition technique for large parts with reduced complexity. The present paper proposes a structured modelling framework to assess whether WAAM could successfully substitute machining processes. The costs, manufacturing times, energy demand and carbon footprint are considered. A case study is presented to clarify and demonstrate the applicability of the proposed methodology.     

Simulation of the manufacturing process chain of welded frame structures

Numerical solutions of manufacturing process chains strongly focus on supporting the production of frame structures in the vehicle industry. Frame structures play a central role in all means of transportation, dominating the total mass in automobiles, trains, airplanes, and even space ships. In the case of automobiles, the frame structure mass constitutes about 30% of the total mass. In the case of the automotive industry, the mass-production, the high-quality standards and the need for mass minimization all increase the necessity to apply virtual manufacturing methods in the production cycle of frame structures. In scope of this paper, a method of chaining the numerical analysis of the structural effect on frame components during successive manufacturing processes is introduced. The change of thermal, metallurgical, and mechanical properties in structures during manufacturing is analyzed by applying theoretical models depending on the identified problem.     

Scalability in manufacturing systems design and operation: State-of-the-art and future developments roadmap

The paper covers the main design, management and operational aspects of scalability in manufacturing systems (MS). It promotes scalability as an area of research of MS theory and practice in order to enhance techniques and methodologies in existing MS paradigms using advanced and emerging design and management approaches and ICT, and meet challenges of emerging MS paradigms and support their promotion and effective and efficient deployment in practice. The paper presents an introduction to scalability, state-of-the art in manufacturing and computer science, and related applications including manufacturing and education and a roadmap for future research and developments.