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Matching the mechanical system of metal forming equipment to reduce life cycle carbon emissions

  • Forming processes as a lever a for boosting the ecological transition
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Abstract

A large number of carbon emissions are generated in the life cycle of metal forming equipment. The movable components are the critical part of the mechanical system in the equipment, which accounts for the carbon emissions in both of manufacturing and use stages. Reducing carbon emissions of the components in the manufacturing stage by lightweight design may result in a significant increment of emissions in the use stage. To overcome the obstacle, a method of matching the mechanical system of metal forming equipment to reduce life cycle carbon emissions is proposed. The effect of the weight of the components that determine the manufacturing’s emission on the configuration of the drive units that determine the emission in the usage stage, was analyzed and quantified. Then, the drive units were reconfigured and optimized to meet the required output force and velocity with the different weights of the components to find the optimal scheme with the lowest emissions in the life cycle. The method was applied to a 2000-ton hydraulic forming equipment, and results indicate that 14.87% of the weight of the movable components can be reduced with a total carbon emissions reduction of 22.48%. The total carbon emissions were reduced by 35.94% compared to that of the movable components through the topology optimization method. The proposed matching method can assist in the low-carbon design of the mechanical system in metal forming equipment.

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Abbreviations

G M :

carbon emissions of the movable components kgCO2eq

G M_M :

carbon emission in manufacturing kgCO2eq

G M_U :

carbon emission caused by the moveable components’ gravity in the use stage kgCO2eq

G RMA :

carbon emissions of raw materials acquisition kgCO2eq

G MP :

carbon emissions of manufacturing processing kgCO2eq

G SR :

carbon emissions of stress relieving process  kgCO2eq

m s i :

mass of steel consumed by the movable component i  kg

k steel :

the carbon emission factor of steel production kgCO2eq/kg

E ij :

electric energy consumption in the process j of component i  kJ

k E :

the carbon emission factor of producing electric energy kgCO2eq/kWh

m ij :

mass of consumed supplemental material in the process j of component i kg

k ij :

the carbon emission factor of consumed supplemental material in the process j of component i kgCO2eq/kg

M ij :

direct carbon dioxide emissions in the process kg

k sr :

electricity consumption scale coefficient in stress relieving kWh/kg

E M_U :

energy consumption of the movable components in the use stage kJ

E U(t):

the energy input of the equipment in use kJ

\({E}_{\mathrm{U}}^{0}(t)\) :

the energy input of the equipment when the weight of the movable components is zero kJ

E U :

energy consumption of metal forming equipment in the whole use cycle kJ

E F(l):

energy consumption of metal forming equipment for forming workpiece l kJ

LP l :

the curvilinear function of the load profile of forming workpiece l -

F l :

required force for metal forming equipment of forming workpiece l N

v l :

required velocity for metal forming equipment of forming workpiece l  m/s

\({E}_{{j}_{1}}\) :

energy consumption of drive unit j1 kJ

\({E}_{{j}_{2}}\) :

energy consumption of transmission unit j2 kJ

\({E}_{{j}_{3}}\) :

energy consumption of execution unit j3 kJ

E l- R :

required energy for forming workpiece l kJ

\({P}_{{\mathrm{in}-j}_{1}}\) :

input power of the drive unit j1 kW

\({\eta }_{\mathrm{m}}\) :

the energy efficiency of the motor  -

\({\eta }_{\mathrm{p}}\) :

the energy efficiency of the pump -

\({P}_{{\mathrm{in}-j}_{2}}\) :

input power of mechanical transmission j2 kW

\({\eta }_{{j}_{2}}\) :

the energy efficiency of mechanical transmission  j2 -

\(\Delta {p}_{{j}_{2}}\) :

Pressure loss of fluid transmission  j2 MPa

\({q}_{{j}_{2}}\) :

the flow of fluid transmission j2 L/min

\({P}_{{\mathrm{in}-j}_{3}}\) :

input power of execution unit j3 kW

\({\eta }_{{j}_{3}}\) :

the energy efficiency of execution unit j3 -

\({P}_{l-r-{j}_{1}}\) :

the output power of the drive unit in operation r of forming the workpiece l kW

t l -r :

time of operation r of forming the workpiece l s

l l -r :

displacement of the movable components in operation r of forming the workpiece l m

E l-r -loss :

total energy loss of the equipment in operation r of forming the workpiece l kJ

\({F}_{l-r-{j}_{1}}\) :

the output force of drive units in operation r of forming the workpiece l N

\({v}_{l-r-{j}_{1}}\) :

required output velocity of the drive units in the operation r of forming the workpiece  l m/s

D(m):

the reconfiguration of the drive unit when the weight of the movable component is m -

G T(m):

total carbon emissions kgCO2eq

M :

the optional set of the weight of the movable components -

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Acknowledgements

The work is financially supported by grants U20A20295 and 52005146 from the National Natural Science Foundation of China and JZ2022HGTB0265 from the Fundamental Research Funds for the Central Universities.

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Authors and Affiliations

  1. School of Mechanical Engineering, Hefei University of Technology, Hefei, 230009, People’s Republic of China

    Xiang Zou, Haihong Huang, Lei Li & Zhifeng Liu

  2. Key Laboratory of Green Design and Manufacturing of Machinery Industry, Hefei University of Technology, Hefei, 230009, People’s Republic of China

    Xiang Zou, Haihong Huang, Lei Li & Zhifeng Liu

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  1. Xiang Zou
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Zou, X., Huang, H., Li, L. et al. Matching the mechanical system of metal forming equipment to reduce life cycle carbon emissions. Int J Mater Form 16, 47 (2023). https://doi.org/10.1007/s12289-023-01772-1

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