 |
 |
 |
 |
 |
We recommend the adoption of technologies, from
machining to clean energy sources to new means of transportation, which
lead to sustainable manufacturing.
New Application of Old Locomotive Model for Passenger Rail Transportation
Amtrak’s Heartland Flyer interstate passenger train and GE Transportation successful trial of Model P32-8, a
biodiesel-fueled passenger locomotive built in Erie (Pennsylvania), is one of TIME magazine’s
list of “The 50 Best Inventions of 2010.”
The appropriately named “Amtrak’s Beef Powered Train” runs on a biodiesel
blend, known as B20, that includes beef byproduct (20% pure biofuel and 80% diesel). It is expected to match or surpass the stationary engine test reductions of hydrocarbons and
carbon monoxide each by 10 percent, particulates by 15 percent
and sulfates by 20 percent.
http://www.amtrak.com/Amtrak_Heartland_Flyer.pdf
Grind Hardening
DMG / Mori Seiki's Machining Technology Laboratory (MTL) has developed a grinding process called “Grind Hardening”, an opportunity for reducing energy use in and the
environmental footprint of typical machining of ferrous materials.
http://www.dmgmoriseikiusa.com/mori-advantage/category/grind-hardening/
Machine Tools Green Design
The use of green design by machine tool manufacturers has become a competitive advantage in 2010 as customers worldwide are adding demands for resources conservation and other sustainable manufacturing attributes. MAG's new SPECHT® 500/630 horizontal machining center is a great example of incorporating green design for the purpose of minimizing energy and water use and overall footprint reduction.
http://www.mag-ias.com/press/2010/new-modular-spechtr-500630-hmc.html
Automated Energy Monitoring of Machine Tools
A. Vijayaraghavan, System Insights Inc., Berkeley, CA
D. Dornfeld, LMAS, University of California, Berkeley
Abstract
Reducing the energy consumption of machine tools can significantly improve the environmental performance of manufacturing systems. To achieve this, monitoring of energy consumption patterns in the systems is required. It is vital in these studies to correlate energy usage with the operations being performed in the manufacturing system. However, this can be challenging due to complexity of manufacturing systems and the vast number of data sources. Event stream processing techniques are applied to automate the monitoring and analysis of energy consumption in manufacturing systems. Methods to reduce usage based on the specific patterns discerned are discussed.
 CIRP-2010-Auto Energy Monitoring.pdf |
Note: The CIRP paper is re-published courtesy of Professor David Dornfeld, Director of the Laboratory for Manufacturing and Sustainability (LMAS) at the University of California, Berkeley.
Dry and Near-Dry Machining
Machining
using coolants (metal removal fluids) or wet machining, although still
dominant, can be replaced with two alternative cutting processes at equal or
better machining performance. The need to replace wet machining is determined
by economic and environmental factors and it leads to sustainable manufacturing
processes. The full-cost or life-cycle cost of coolant is estimated at 15 – 20%
of the operational cost of a machining process. The full cost includes the
costs of purchasing, infrastructure for coolant and air filtration, circulation
and disposal, regulatory compliance, machine maintenance.
Dry
cutting with no fluid is currently feasible mostly for roughing, milling operations,
on a limited number of materials (aluminum, cast iron, carbon steel) using
tools with special coating and chip breakers. Near-dry cutting or MQL (Minimum
Quantity Lubrication) is a hybrid process between the wet (flooded,
conventional coolant/water mixture) and the dry cutting, which can be applied
to a larger set of operations (finishing, drilling) and materials, with much
reduced environmental and operational costs. MQL uses the minimum quantity of
oil/air finely atomized mist (milliliters/hour) delivered directly at the
cutting edge in contact with the machined part. MQL usually uses biodegradable
vegetable or synthetic oil as cutting fluid.
Both
dry and near-dry processes fit the requirements of a sustainable manufacturing
process by reducing energy consumption, cycle-time, mist emissions,
bio-hazardous waste, water volume, operating costs, machine maintenance and
improving working conditions, air quality, chip recovery and recycling, tool
lifetime.
MQL
has been successfully adopted in mass manufacturing systems, particularly in
the automotive and aerospace industry. Job shops, contract manufacturers, other
mass manufacturing companies could implement the two sustainable cutting processes
by requiring their suppliers to retrofit existing machines for MQL, where
feasible, or investing only in new machines which offer MQL in their design and
control system.
One
of the industry benchmarks for MQL adoption, as part of the overall corporate strategy
for sustainability, is Ford Motor Company.
For training purposes, we recommend the "Minimum Quantity Lubrication" DVD offered by the Society of Manufacturing Engineers:
http://sme.org/cgi-bin/get-item.pl?DV07PUB10&2&SME&
Strategies for Minimum Energy Operation for Precision Machining
Nancy Diaz, Moneer Helu, Andrew Jarvis,
Stefan Tönissen, David Dornfeld, Ralf Schlosser
Laboratory for Manufacturing and Sustainability,
University of California, Berkeley, WZL, RWTH Aachen
Abstract
The development of "green" machine tools will require novel approaches for design, production and operation for energy savings and reduced environmental impact. We describe here work on three projects: i. influence of process parameters on power consumption of end-milling using force and process time models with experimental verification. Process parameters are chosen to minimize process time since power consumed by a machine tool is essentially independent of the load and energy per unit manufactured decreases with process time; ii. KERS (kinetic energy recovery system) for machine design and modeling the integration of a recovery system into a machine tool to calculate the amount of energy that could be recovered, and whether the environmental benefits are significant; and iii. evaluation of interoperability solutions, such as MTConnect, as tools enabling a standardized "plug-and-play" platform to integrate sensors with a unified monitoring scheme to achieve improved energy performance.
Dornfeld-MTTRF-2009.pdf |
Note: The MTTRF paper is re-published courtesy of Professor David Dornfeld, Director of the Laboratory for Manufacturing and Sustainability (LMAS) at the University of California, Berkeley.
