Energy Efficient Manufacturing

John W. Sutherland received his PhD from the University of Illinois at Urbana-Champaign and is a Professor and holds the Fehsenfeld Family Headship of Environmental and Ecological Engineering (EEE) at Purdue University. He is one of the world’s leading authorities on the application of sustainability principles to design, manufacturing, and other industrial issues. He has published more than 300 papers in various journals and conference proceedings, authored several book chapters, and is co-author of the text "Statistical Quality Design and Control: Contemporary Concepts and Methods". He is a Fellow of the Society of Manufacturing Engineers, American Society of Mechanical Engineers, and CIRP (International Academy for Production Engineering). His honors and recognitions include the SME Outstanding Young Manufacturing Engineer Award, Presidential Early Career Award for Scientists and Engineers, SAE Ralph R. Teetor Award, SME Education Award, SAE International John Connor Environmental Award, and ASME William T. Ennor Manufacturing Technology Award.David A. Dornfeld received his Ph.D. in Mechanical Engineering from UW-Madison in 1976 and was Will C. Hall Family Professor and Chair of Mechanical Engineering at University of California Berkeley. He led the Laboratory for Manufacturing and Sustainability (LMAS) and the Sustainable Manufacturing Partnership studying green/sustainable manufacturing; manufacturing processes; precision manufacturing; process monitoring and optimization. He published over 400 papers, authored three research monographs, contributed chapters to several books and had seven patents. He was a Member of the National Academy of Engineering (NAE), a Fellow of American Society of Mechanical Engineers (ASME), recipient of ASME/SME M. Eugene Merchant Manufacturing Medal, 2015, Ennor Award, 2010 and Blackall Machine Tool and Gage Award, 1986, Fellow of Society of Manufacturing Engineers (SME), recipient of 2004 SME Fredrick W. Taylor Research Medal, member Japan Society of Precision Engineering (JSPE) and recipient of 2005 JSPE Takagi Prize, Fellow of University of Tokyo Engineering and Fellow of CIRP (International Academy for Production Engineering). He passed away in March 2016.Barbara S. Linke obtained her diploma and doctoral degree in Mechanical Engineering from the RWTH Aachen University, Germany. She worked at the Laboratory for Machine Tools and Production Engineering WZL from 2002 – 2010 on grinding technology and tooling engineering. From 2010 - 2012, Barbara was a research fellow at the University of California Berkeley. Since November 2012, Barbara Linke has been an assistant professor at the University of California Davis.

• 1 Introduction to Energy Efficient Manufacturing 1Barbara S. Linke and John W. Sutherland1.1 Energy Use Implications 21.2 Drivers and Solutions for Energy Efficiency 3References 92 Operation Planning & Monitoring 11Y.B. Guo2.1 Unit Manufacturing Processes 112.2 Life Cycle Inventory (LCI) of Unit Manufacturing Process 132.3 Energy Consumption in Unit Manufacturing Process 162.3.1 Basic Concepts of Energy, Power, and Work 162.3.2 Framework of Energy Consumption 172.4 Operation Plan Relevance to Energy Consumption 192.5 Energy Accounting in Unit Manufacturing Processes 202.6 Processing Energy in Unit Manufacturing Process 212.6.1 Cases of Processing Energy Modeling 212.6.1.1 Forging 212.6.1.2 Orthogonal Cutting 222.6.1.3 Grinding 242.6.1.4 Specific Energy vs. MRR 252.6.2 Energy Measurement 262.7 Energy Reduction Opportunities 262.7.1 Shortening Process Chain by Hard Machining 282.7.2 Substitution of Process Steps 282.7.3 Hybrid processes 292.7.4 Adaptation of Cooling and Flushing Strategies 292.7.5 Remanufacturing 30References 303 Materials Processing 33Karl R. Haapala, Sundar V. Atre, Ravi Enneti, Ian C. Garretson and Hao Zhang3.1 Steel 343.1.1 Steelmaking Technology 353.2 Aluminum 363.2.1 Aluminum Alloying 373.2.2 History of Aluminum Processing 373.2.3 Aluminum in Commerce 383.2.4 Aluminum Processing 413.2.5 Bayer Process 423.2.6 Preparation of Carbon 443.2.7 Hall-Heroult Electrolytic Process 443.3 Titanium 453.3.1 Titanium Alloying 463.3.2 History of Titanium Processing 473.3.3 Titanium in Commerce 483.3.4 Titanium Processing Methods 493.3.5 Sulfate Process 503.3.6 Chloride Process 513.3.7 Hunter Process and Kroll Process 513.3.8 Remelting Processes 523.3.9 Emerging Titanium Processing Technologies 523.4 Polymers 543.4.1 Life Cycle Environmental and Cost Assessment 593.4.2 An Application of Polymer-Powder Processes 59References 614 Energy Reduction in Manufacturing via Incremental Forming and Surface Microtexturing 65Jian Cao and Rajiv Malhotra4.1 Incremental Forming 664.1.1 Conventional Forming Processes 664.1.2 Energy Reduction via Incremental Forming 724.1.3 Challenges in Incremental Forming 754.1.3.1 Toolpath Planning for Enhanced Geometric Accuracy and Process Flexibility 764.1.3.2 Formability Prediction and Deformation Mechanics 854.1.3.3 Process Innovation and Materials Capability in DSIF 924.1.3.4 Future Challenges in Incremental Forming 954.2 Surface Microtexturing 974.2.1 Energy Based Applications of Surface Microtexturing 974.2.1.1 Microtexturing for Friction Reduction 974.2.1.2 Microtexturing Methods 1014.2.1.3 Future Work in Microtexturing 1144.3 Summary 1154.4 Acknowledgement 116References 1165 An Analysis of Energy Consumption and Energy Efficiency in Material Removal Processes 123Tao Lu and I.S. Jawahir5.1 Overview 1235.2 Plant and Workstation Levels 1265.3 Operation Level 1295.4 Process Optimization for Energy Consumption 1345.4.1 Plant Level and Workstation Level 1345.4.2 Operation Level 1375.4.2.1 Turning Operation 1375.4.2.2 Milling Operation 1455.4.2.3 Drilling Operation 1485.4.2.4 Grinding Operation 1505.5 Conclusions 152Reference 1546 Nontraditional Removal Processes 159Murali Sundaram and K.P. Rajurkar6.1 Introduction 1596.1.2 Working Principle 1606.1.2.1 Electrical Discharge Machining 1606.1.2.2 Electrochemical Machining 1616.1.2.3 Electrochemical Discharge Machining 1636.1.2.4 Electrochemical Grinding 1646.2 Energy Efficiency 165Acknowledgments 167References 1677 Surface Treatment and Tribological Considerations 169S.R. Schmid and J. Jeswiet7.1 Introduction 1707.2 Surface Treatment Techniques 1737.2.1 Surface Geometry Modification 1747.2.2 Microstructural Modification 1757.2.3 Chemical Approaches 1797.3 Coating Operations 1797.3.1 Hard Facing 1797.3.2 Vapor Deposition 1837.3.3 Miscellaneous Coating Operations 1857.4 Tribology 1897.5 Evolving Technologies 1917.5.1 Biomimetics – Biologically Inspired Design 1917.6 Micro Manufacturing 1927.7 Conclusions 194References 1948 Joining Processes 197Amber Shrivastava, Manuela Krones and Frank E. Pfefferkorn8.1 Introduction 1988.2 Sustainability in Joining 2008.3 Taxonomy 2038.4 Data Sources 2058.5 Efficiency of Joining Equipment 2088.6 Efficiency of Joining Processes 2108.6.1 Fusion Welding 2118.6.2 Chemical Joining Methods 2148.6.3 Solid-State Welding 2168.6.4 Mechanical Joining Methods 2188.6.4.1 Mechanical Fastening 2188.6.4.2 Adhesive Bonding 2198.7 Process Selection 2208.8 Efficiency of Joining Facilities 2218.9 Case Studies 2248.9.1 Submerged Arc Welding (SAW) 2248.9.2 Friction Stir Welding (FSW) 228Reference 2359 Manufacturing Equipment 239M. Helu, N. Diaz-Elsayed and D. Dornfeld9.1 Introduction 2399.2 Power Measurement 2409.3 Characterizing the Power Demand 2429.3.1 Constant Power 2429.3.2 Variable Power 2449.3.3 Processing Power 2449.4 Energy Model 2449.5 Life Cycle Energy Analysis of Production Equipment 2469.6 Energy Reduction Strategies 2479.6.1 Strategies for Equipment with High Processing Power 2489.6.2 Strategies for Equipment with High Tare Power 2499.6.2.1 Process Time 2499.6.2.2 Machine Design 2519.7 Additional Life Cycle Impacts of Energy Reduction Strategies 2529.8 Summary 254References 25610 Energy Considerations in Assembly Operations 261Camelio, J.A., McCullough, D., Prosch, S. and Rickli, J.L.10.1 Introduction to Assembly Systems & Operations 26210.2 Fundamentals of Assembly Operations 26310.3 Characterizing Assembly System Energy Consumption 26410.3.1 Indirect Energy 26510.3.2 Direct Energy 26610.4 Direct Energy Considerations of Assembly Joining Processes 26810.4.1 Mechanical Assembly 26810.4.2 Adhesive Bonding 26910.4.3 Welding, Brazing, and Soldering 27210.5 Assembly System Energy Metrics 27510.6 Case Study: Heavy Duty Truck Assembly 28010.6.1 Case Study Energy Consumption Analysis Approach 28010.6.2 Assembly Process Categorization 28110.6.3 Case Study Energy Analysis Results 28510.6.4 Discussion and Recommendations 29210.7 Future of Energy Efficient Assembly Operations 293References 294Appendix 10.A 29611 Manufacturing Facility Energy Improvement 299Chris Yuan, Junling Xie and John Nicol11.1 Introduction 30011.2 Auxiliary Industrial Energy Consumptions 30311.2.1 Lighting 30311.2.1.1 Lighting Technologies 30411.2.1.2 Opportunities for Improving Energy Efficiency of Industrial Lighting 30511.2.2 HVAC 30711.2.2.1 HVAC Systems 30811.2.2.2 HVAC Energy Efficiency Opportunities 31011.2.3 Compressed Air 31511.2.3.1 Compressed Air Technologies 31611.2.3.2 Improving Energy Efficiency of Air Compressors 31711.3 Industrial Practices on Energy Assessment and Energy Efficiency Improvement 32111.3.1 Types of Energy Assessments 32111.3.2 Energy Assessment Procedures 32211.4 Energy Management and its Enhancement Approaches 32311.4.1 Energy Management Description and Benefits 32411.4.2 Establishing an Energy Management Approach 32611.4.2.1 ISO 50001 33611.5 Conclusions 337References 33812 Energy Efficient Manufacturing Process Planning 339RuixueYin, Fu Zhao and John W. Sutherland12.1 Introduction 33912.2 The Basics of Process Planning 34112.2.1 Types of Production 34212.2.2 Process Planning Procedure 34412.2.3 Process Planning Methods 34612.3 Energy Efficient Process Planning 35012.3.1 Energy Consumption and Carbon Footprint Models of Manufacturing Processes 35012.3.2 A Semi-Generative Process Planning Approach for Energy Efficiency 35112.4 Case Study 35312.5 Conclusions 357Reference 35813 Scheduling for Energy Efficient Manufacturing 359Nelson A. Uhan, Andrew Liu and Fu Zhao13.1 Introduction 35913.2 A Brief Introduction to Scheduling 36013.2.1 Machine Environments 36013.2.2 Job Characteristics 36213.3.3 Feasible Schedules and Gantt Charts 36213.2.4 Objective Functions: Classic Time-Based Objectives 36413.3 Machine Environments 36513.4 Job Characteristics 36713.4.1 A Very Brief Introduction to Mathematical Optimization 36813.4.2 A Time-Indexed Integer Linear Program for the Energy-Efficient Flow Shop Problem 37013.4.3 Algorithms for Solving Integer Linear Programs 37613.5 Conclusion and Additional Reading 377References 37914 Energy Efficiency in the Supply Chain 381Thomas J. Goldsby and Fazleena Badurdeen14.1 Supply Chain Management 38114.2 Supply Chain Structure 38214.3 Supply Chain Processes 38514.3.1 Customer Relationship Management 38714.3.2 Supplier Relationship Management 38814.3.3 Customer Service Management 38914.3.4 Demand Management 39014.3.5 Manufacturing Flow Management 39114.3.6 Order Fulfillment 39214.3.7 Product Development and Commercialization 39314.3.8 Returns Management 39414.4 Supply Chain Management Components 39514.5 Conclusion 396References 396Endnotes 40015 Business Models and Organizational Strategies 401Omar Romero-Hernandez, David Hirsch, Sergio Romero and Sara Beckman15.1 Introduction 40215.2 Reference Framework for Selection of Energy Efficiency Projects 40415.2.1 Mission and Drivers 40515.2.2 Set Level of Assessment 40515.2.3 Recognize Opportunities and Risk 40615.2.4 Select Projects 40615.2.5 Implementation and Communication 40715.3 Common Energy Efficiency Opportunities 40815.3.1 Building Envelope 40815.3.2 Heating, Ventilation and Air Conditioning (HVAC) 40915.3.3 Efficient Lighting 41015.3.4 Efficient Motors and Systems 41115.3.5 Building Management Systems 41215.4 Stakeholders 41315.4.1 Tenants and Owners 41315.4.2 Regulators 41415.4.3 Banks/Lenders 41415.4.4 Energy Service Companies (ESCOs) 41515.4.5 Business Models 41515.5 Conclusions 417References 41716 Energy Efficient or Energy Effective Manufacturing? 421S. A. Shade and J. W. Sutherland16.1 Energy Efficiency: A Macro Perspective 42216.1.1 Government Perspective 42216.1.2 Company Perspective 42316.2 The Basics of Energy Efficiency 42516.3 Limitations of Energy Efficiency 43316.4 Energy Effectiveness 43616.4.1 Effectiveness – It’s Up to the Decision Maker 43816.4.2 Effectiveness – A Choice on Where to Invest 43916.4.3 Effectiveness – Is An Action Really Worthwhile? 43916.5 Summary 44216.6 Acknowledgments 443References 443Index 445