Electrical energy and material efficiency analysis of machining, additive and hybrid manufacturing

Wippermann, Andi; Gutowski, Timothy G.; Denkena, Berend; Dittrich, Marc-André; Wessarges, Yvonne

doi:10.1016/j.jclepro.2019.119731

Cited by 46 publications

(11 citation statements)

References 20 publications

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“…The DED process needs additional post-processing to improve the surface roughness and the geometrical accuracy of the fabricated part, as shown in Fig. 15 [36,42,55,57,119,143,147,226,227]. An additional post-process is generally performed on a different apparatus in separate shop floors [55,57,227].…”

Section: Hybrid Am Processes and Systemsmentioning

confidence: 99%

“…Cortina et al [227] summarized the benefits of the hybrid system; (a) no need to change part during manufacturing, (b) reduction of material movement inside the factory, (c) manufacture of parts with higher complexity, (d) decrease in BTF, (e) reduced factory space, (f) simplicity for operator, (g) lower overall investment, and (h) reduced cost of the final part. Most research works and developed systems related to the HAM process were focused on the combination of DED with machining processes [24,36,42,55,57,119,143,147,226,227]. Features of HAM processes and systems are summarized in Table 11.…”

Section: Hybrid Am Processes and Systemsmentioning

confidence: 99%

“…Since a shape deposition manufacturing (SDM) process was developed by Carnegie Mellon University in U.S.A, various HAM processes based on DED processes were introduced, as shown in Table 11 and Fig. 16 [36,55,57,226,227].…”

Section: Hybrid Am Processes and Systemsmentioning

confidence: 99%

See 2 more Smart Citations

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

274

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Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily fabricate a heterogeneous material with desired properties and characteristics via successive and simultaneous depositions of different materials. In addition, a hybrid process combining DED with different manufacturing processes can be conveniently developed. Hence, researches on the DED processes have been steadily increased in recent years. This paper reviewed recent research trends of DED processes and their applications. Principles, key technologies and the state-of-the art related to the development of process and system, the optimization of deposition conditions and the application of DED process were discussed. Finally, future research issues and opportunities of the DED process were identified.

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Section: Hybrid Am Processes and Systemsmentioning

confidence: 99%

Section: Hybrid Am Processes and Systemsmentioning

confidence: 99%

See 1 more Smart Citation

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

274

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“…Energy consumption in manufacturing is directly related to greenhouse gas emissions. 2 Therefore, there is a need to discover new ways for analyzing and modeling energy consumption in machining processes in order to increase energy efficiency.…”

Section: Introductionmentioning

confidence: 99%

Comparison of minimum quantity lubrication and wet milling based on energy consumption modeling

Bayat

Abootorabi

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Estimating the energy consumed by machining process is substantial because it has a large share of environmental effects in the manufacturing industry. In this paper, a generic energy consumption model was developed for milling processes that is able to be applied in all milling machine tools. Energy consumption of each segment was estimated according to power characteristics and parameters extracted from numerical control (NC) codes, then the total energy consumption was estimated by adding energy consumption of the machine components. Energy consumption of milling process was measured and compared in conventional (wet) and minimum quantity lubrication (MQL) conditions. The developed method was verified by comparing the estimated values of energy consumption with experimental results. Various studies have suggested different types of energy consumption modeling with machining, however; only a few studies have focused on the use of these modeling techniques. Thus, the MQL method has been rarely compared with the wet milling in terms of energy consumption. In the proposed model, energy consumption for workpiece adjustment, accounting for a major part of the costs in machining economics was considered for the first time. The results showed that the proposed method is efficient and practical for predicting energy consumption, with the possibility of occurring 5% error. Analysis of the results revealed that using the MQL method in milling process leads to 33% lower power consumption than wet milling and therefore, the MQL method can reduce the cost of production.

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“…In fact, the industrial sector exerts a key role in the global economy [17], as well as from the environmental viewpoint. On the one hand, the manufacturing sector uses significant amounts of energy, and this is also reflected on the energy market [18]. On the other hand, the climate change and the shortage of resources [19] make it necessary to undertake an urgent and responsible use of energy through more efficient and sustainable manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

Atzeni

Catalano

Priarone

et al. 2021

Int J Adv Manuf Technol

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Additive manufacturing (AM) processes allow complex geometries to be produced with enhanced functionality, but technological challenges still have to be dealt with, in terms of surface finish and achieved tolerances. Among the consolidated powder-bed fusion processes, electron beam melting (EBM), which allows almost stress-free parts to be manufactured with a high productivity and minimum use of support structures, suffers from a poor surface quality. Thus, finishing processes have to be performed. The same geometrical complexity, which is considered one of the benefits of AM, becomes an issue when finishing is applied, in particular when internal features are present. Unconventional isotropic superfinishing processes could be a solution to this problem since they can generate a low surface roughness on complex geometries. However, the performance characteristics, with regard to the environmental sustainability and economic aspects, need to be evaluated since they are key factors that must be considered for decision-support tools when selecting a finishing process. The technological feasibility of the isotropic superfinishing (ISF) process, applied to Ti-6Al-4V parts produced by electron beam melting, is investigated in this paper by considering the dimensional and geometrical deviations induced by the finishing treatment, and from observations of the surface morphology. A significant reduction in surface roughness, Sa, to around 4 μm, has been observed on the most irregular surfaces, although the original shape is maintained. Environmental sustainability has been analyzed for all the manufacturing steps, from powder production to part fabrication, to the finishing process, and both the cumulative energy demand and material waste have been accounted for. The economic impact of the whole manufacturing chain has been evaluated, and the advantages of the ISF process are pointed out.

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Electrical energy and material efficiency analysis of machining, additive and hybrid manufacturing

Cited by 46 publications

References 20 publications

Directed Energy Deposition (DED) Process: State of the Art

Directed Energy Deposition (DED) Process: State of the Art

Comparison of minimum quantity lubrication and wet milling based on energy consumption modeling

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

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