Le tecnologie sottrattive e la sostenibilità

Transcription

1 Sostenibilità delle tecnologie manifatturiere: dalla teoria alla pratica 29 Gennaio 2018 ITIA-CNR Milano Le tecnologie sottrattive e la sostenibilità Paolo C. Priarone Politecnico di Torino, Department of Management and Production Engineering Corso Duca degli Abruzzi, Torino, Italy Politecnico di Torino

2 Why Sustainable Manufacturing? 2 Environmental stress increase Global Footprint Network (2017) The carbon footprint makes up 60% of humanity s Ecological Footprint. Reducing the carbon component of humanity s Ecological Footprint by 50% would move the date of Overshoot Day by 89 days, or about three months.

3 Why Sustainable Manufacturing? 3 Environmental responsibility of the manufacturing sector Breakdown analysis of the World CO 2 emission by sectors in 2013 International European Agency, IEA (2014) Gutowski et al. (2013)

4 Sustainability in material removal processes 4 LCA/LCI of manufacturing processes Process design and optimization in view of sustainable development Eco-sustainable lubricoolant strategies Cryogenic-assisted cutting Recycling-related issues Source: Internet

5 LCA/LCI of manufacturing processes 5 Cutting tool manufacturing: a sustainability perspective Raw material: HSS round bar (Ø 10.5 mm, L = 3.2 m) Machining stage: 1 Turning/Milling Energy consumption: 1.64 kwh/piece Flutes grinding 61.3 % F/C: 34.2 % MT: 27.1 % MT: Machine tool F/C: Filtering/Cooling equipments Quenching (outsourced) Machining stage: 2 Shank grinding Machining stage: 3 Flutes grinding Workpiece Electricity Cutting tools Lubricants Oils Water i-th machining stage Machine tool + Auxiliary apparatus (Semi-) finished part Material scraps Consumption of: - Energy - Cutting tools - Lubricants/Oils - Water Shank grinding 15.7 % Turning/Milling 2.0 % Estimated oil consumption: 33 ml/piece MT: 2.8 % F/C: 18.2 % 71.1 % Threads grinding 21.0 % Flutes grinding Machining stage: 4 Threads grinding 15.5 % 2.2 % 11.1 % Threads grinding Turning / Milling Shank grinding Finished product Castrol 15.5 % Shell 84.5 %

6 Process design and optimization in view of sustainable development 6 Quality-oriented optimization of energy consumption in a grinding process. Key: (np; vw; vc) (-1; 0; 0) Vitrifiedbonded wheel (-1; -1; +1) (-1; -1; -1) Resinoidbonded wheel (+1; +1; +1) 1.0 (+1; +1; -1) (+1; 0; 0) (+1; -1; +1) Target: Energy saving Power, P (kw) Acquired power signal (-1; +1; -1) (-1; +1; +1) (+1; -1; -1) (+1; -1; -1) (0; 0; 0) (-1; +1; +1) K1 = 0; K2 = 1 K1 = 0.25; K2 = 0.75 K1 = 0.50; K2 = 0.50 K1 = 0.75; K2 = 0.25 K1 = 1; K2 = Process time, t (s) Resinoid-bonded grinding wheel Vitrified-bonded grinding wheel (+1; -1; +1) (-1; +1; -1) (+1; 0; 0) (-1; 0; 0) Target: Surface quality (+1; +1; -1) (+1; +1; +1) (-1; -1; +1) (-1; -1; -1) 500 μm np:+1; vw :+1; vc :-1 np:+1; vw :+1; vc : μm

7 Process design and optimization in view of sustainable development 7 Re-thinking the maximum efficiency in machining Four process metrics: process time, t (s) process cost, C ( ) primary energy demand, E (J) carbon dioxide emissions, CE (kg) Metric = n i= 1 Contribution i Kalpakjian and Schmid (2001) Direct and indirect contributions System boundaries

8 Process design and optimization in view of sustainable development 8 Re-thinking the maximum efficiency in machining Ti-6Al-4V Wet cutting a p = 0.5 mm; f = 0.15 mm/rev Specific process time, U t 8.0 ( 10-3 s/mm 3 ) Maximum process efficiency (Cost- and time-based) U t min U C min Specific process cost, U C ( 10-4 /mm ) Key: Specific process energy, 205 U E min VB B max (mm): U E (J/mm 3 ) E Specific carbon 8.00E-06 dioxide emissions, 7.50E-06 U CE ( 10-6 kgco 2 /mm 7.00E-06 3 ) U CE min 6.50E MRR (mm 3 /s) v c (m/min)

9 Eco-sustainable lubricoolant strategies 9 Comparison among different lubricoolant strategies: dry cutting, conventional flood cooling, Minimum Quantity Lubrication (MQL), Minimum Quantity Cooling (MQC), cryogenic assisted-machining. In cooperation with:

10 Eco-sustainable lubricoolant strategies 10 Cryogenic-assisted cutting Turning Milling

11 Recycling-related issues 11 Analysis of recycling benefits awarding in manufacturing Performance of cutting tools produced from WC-Co scraps In cooperation with:

12 Comparison among different manufacturing processes 12 Machining vs. Forming In cooperation with:

13 Sostenibilità delle tecnologie manifatturiere: dalla teoria alla pratica 29 Gennaio 2018 ITIA-CNR Milano Le tecnologie sottrattive e la sostenibilità Thanks for your kind attention Paolo C. Priarone Politecnico di Torino Dept. of Management and Production Engineering Corso Duca degli Abruzzi, Torino, Italy paoloclaudio.priarone@polito.it