Sustainable Manufacturing

Energy efficiency of manufacturing systems and

manufacturing units

MAG Stiftungslehrstuhl für Fertigungstechnologien

Chinesisch-Deutsches Hochschulkolleg der Tongji-Universität

Prof. Dr. –Ing ZHANG Weimin

Outline

Background 1

High energy efficiency workshop 2

High energy efficiency machine tools 3

Advanced manufacturing process 4

Background

Sustainable development of Global, China & Tongji University

The core is Develop & Sustainable

To eliminate poverty and hunger;

To feed, nurture, house, educate

and employ the global population

To ensure peace, security

and freedom;

To preserve the Earth’s basic life

support systems.

Global sustainable development problem

213.46

258.68 291.45

324.94

361.73

152.51 184.95

209.30 232.02

252.46

123.00 151.27

172.11 189.41 205.67

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

2004 2006 2008 2010 2012

Total Energy Consumption (Bntce) Total industrial energy consumption (Bntce)Total manufacturing energy consumption Bntce)

• Sustainability of China

0.218

0.519

0.118 0.124

0.255

0.306

15094

7298 5869

3577

0

2000

4000

6000

8000

10000

12000

14000

16000

0.000

0.100

0.200

0.300

0.400

0.500

0.600

USA China Japan Germany World Asia

Energy consumption per unit GDP（TCE/k$） GDP（bn$）

Source:IMF2012

GDP USA(1) China(2) Japan(3) Germany(4)

Energy consumption per unit GDP rank USA(27) China(55) Japan(6) Germany(9)

World rank（2012）

The past 30 years, China's GDP grew by 15 times, while energy consumption increased by nearly four times, the main resource consumption and pollutant emissions per unit GDP is much higher than in developed countries

Source:IMF2012

The total energy consumption increase every year, but the growth rate decreased. Manufacturing share of energy consumption is about 56%

Energy consumption Source:NSBC

Annual Report from 1999

Science and technology innovation

En

erg

y s

avin

g

En

viro

nm

en

tal

Circ

ula

r

Eco

no

my

Re

so

urc

es

Renew

able

Ne

w E

ne

rgy

Re

so

urc

e

……

Society

Sustainable

Economic Sustainable

Ecology Sustainable

• Sustainability of China

Technological innovation is the basis, energy-saving technology, environmental technology etc as support.

Chinese government attaches great importance to sustainable development

Tongji University, “Institute of Environment for Sustainable Development”

Shandong University, “Research Center for Sustainable Manufacturing”

Dalian University of Technology, "Sustainable Design and Manufacturing Institute.“

Chongqing University, “Institute of Manufacturing Engineering”

Hefei University of Technology, “Green Design and Manufacturing Engineering”

……

• Universities actively participate

MOST, NSFC ,973 and 863 supports funded researcher for green manufacturing, remanufachturing, sustainable manufacturing, low-carbon manufacturing projects every year, which has made many achievements and partial results into applications.

• National research funds support

China and German manufacturing

• China has a rapid GDP growth, and manufacturing accounts for GDP than the major. China is a big but not power manufacturing country. The German economy is well developed, and it is a power manufacturing country.

• German trade close contacts, trade volume

• Mechanical and electrical products are an important component of trade between the two countries

Source： NSBC & MOFCOM

34.17 45%

10.22 13%

6.36 8%

4.52 6%

3.46 5%

17.63 23%

Germany import from china(bn $)

Mechanical and electricalproducts

Textiles and raw materials

Miscellaneous products,furniture, toys

Base metals and articles

Chemical products

Others

total 76.36 bn$

34.91 39%

28.02 31%

6.48 7%

6.07 7%

5.30 6%

8.59 10%

Germany export to China(bn $)

Mechanical and electricalproductsTransport equipment

Optical, watches, medicalequipmentChemical products

Base metals and articles

Others

total 89.36 bn$

59.21 49.92 68.05 76.40 69.21 76.362

55.79 55.72

74.26

92.74 91.92

89.36

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

2008 2009 2010 2011 2012 2013

China imports from German(bn $)

• Overview of China and German

70

166

2004年 2013年

China-German bilateral mechanical

equipment trade volume（bn RMB）

German machinery products mutually market their own merits. Overall, the German machinery products to China have obvious advantages.

Machine tools exporting to China are much larger than imports from China

High-precision, high-performance machine tools is the trend of the development in both countries.

17 16.4

3.8 4

2012 2013

Machine Export to China（bn EUR）

Machine Import from China（bn EUR）

Source: VDW & VDMA

Construction equipment and building material machinery, Mining equipment, Foundry machinery, Safes and strongroom installations

Machine tools, Agricultural machinery, Food processing and packaging machinery, Process plant and equipment, Fluid power equipment, Printing and paper equipment and supplies, Cleaning systems, Power Systems, Engines and systems.

Source: VDW

Source: VDW

• Machine & Mechanical equipment trade between China and German

• Superiority of China& German Manufacturing

• Main problems｜面临的主要问题[1]

70% -80% of the

industrial energy

50% of national energy

costs

Improve

energy

efficiency

Demand for raw materials

increased by nearly 70%

(2001 to 2008)

30%-80% of

manufacturing costs

Improve

resource

efficiency

Energy｜能源

Resource｜资源

5% of industrial waste

generated by machinery

manufacturing industry

Rank 4th after chemical, oil,

coal and metal smelting

industry

More than 6 billion tons of

carbon emissions in 2008

The world's largest carbon

emissions producer

Discharge｜废物排放

Reduce

carbon

emissio

ns

[1] National Bureau of statistics of China . China Statistical Yearbook 2005 ( M ). China Statistical Yearbook .2005.11.

Background of China manufacturing industry

Goal: Machine Tool with high productivity and high energy efficiency

Sustainable Manufacturing

Solution

China Development and Reform Commission: carbon taxes may begin in the "12 5" period .

• National medium-and long-term science and technology development plan (2006-2020) clearly

states that: the manufacture resource consumption, environmental load level must be reduced to

the ranks of the advanced international

• Executive meeting of the State Council of China announced on November 26, 2009: by 2020,

China's carbon dioxide emissions per unit of GDP decreased by 40% -45% compared to 2005.

Energy saving

Protection of basic energy

Limit excessive energy

Encourage saving energy

[1]. http://news.xinhuanet.com/fortune/2010-10/30/c_12719909_2.htm：节能·低碳·变革--国家能源局副局长吴吟解读“十二五”

规划能源领域三个关键词.

Low carbon

Low carbon concept

Low-carbon economy

Low-carbon society

Low-carbon technologies

Change

Energy use

Mode of production

Build a safe, stable,

economic, clean modern

energy industry system

Background

Chinesische Enviroment Energy Exchange

http://www.shanghai.gov.cn/shanghai/node2314/node2319/node12344/u26ai32789.html

http://www.cbeex.com.cn/ http://www.cneeex.com/ http://www.chinatcx.com.cn/tcxweb/

Tongji University have research a lot in sustainable development of university & country, and has gained rich achievements in sustainable manufacturing, green cars, green architecture etc.

• Sustainability of Tongji University

Green Energy

Smart Urban Factory

Smart Products

Green Manufacture

High efficiency Machine tools

Green Material

Advanced manufacturing process

Industry 4.0 smart Product is consist of Smart Urban Factory and Green Manufacture. And high efficiency workshop, high efficiency machine tools and advanced production process are important supports.

High efficiency workshop

Process and sustainable manufacturing

http://www.idnovo.com.cn/zhizao/2012/0531/article_12112.html

• National Science and Technology Major Project of Ministry of Science and Technology of China (Grant No. 2011 ZX04016-021)

Key technology and innovation platform of high speed / composite CNC machine tools • National Science and technology support program（Issue number: 2012BAF01B02）

Subject name: High speed and high precision CNC machine, tool key technology development and application of green manufacturing model。

• National Science and Technology Major Project of Ministry of Science and Technology of China (Grant No. 2012ZX04005031).

High speed / composite CNC machine tools and key technology innovation platform

• Current Projects

• Partners

Research interests: 研究方向：

• Lightweight design of high speed precision machine tools

高速精密机床的轻量化设计

• Energy saving technology of high speed precision CNC machine tool

高速精密数控机床的节能技术

• Green process technology for high speed precision CNC machine tool

高速精密数控机床绿色工艺技术

Classification of cutting machine tools : 切削加工中的机床分级研究：

单位功效碳足迹

噪声

粉尘浓度

油雾浓度

刺激性气味

2kg-CO /kg/cycle（ ）

3mg/m /cycle（ ）3mg/m /cycle（ ）

××

dB/ cycle（ ）

1

2

3

4

5

机床能效属性标识Re & En Label for Machine Tools

生产者名称 ___________________________

规 格 型 号 ___________________________

依据国家标准： GB xxxx.xxxx

好

中等

差

××

××

××

××

Different cutting method 不同的加工方法

Energy saving potential analysis

Classification of cutting machine tools

45,000kWh/year(1)

(165,000kWh/year(2))

(1)7.5kW bei 6000 h/a(PTW

TU Darmstadt, 2008)

(2)22kW bei 7500 h/a

(IWB TU Muenchen, in

Fertigung S.:30-32, 9-

2009) 1kWh equals

0.63kg CO2

10 X 10000km/year

(277g CO2/km)

4500€/year

In the huge energy consumption of machine tool, only 22% of the energy are used to cut off material!

Classification of cutting machine tools • Guide user to buy a more efficient machine tool • Promote machine tool company produce more

efficient machine tool • Support the government environmental policy • … …

单位功效碳足迹

噪声

粉尘浓度

油雾浓度

刺激性气味

2kg-CO /kg/cycle（ ）

3mg/m /cycle（ ）3mg/m /cycle（ ）

××

dB/ cycle（ ）

1

2

3

4

5

机床能效属性标识Re & En Label for Machine Tools

生产者名称 ___________________________

规 格 型 号 ___________________________

依据国家标准： GB xxxx.xxxx

好

中等

差

××

××

××

××

Energy & Resource label for machine tools

机床能效属性标识

• Parameters for

manufacturing

• Energy efficiency

• Resource efficiency

• Ecological impact

(Carbon footprint)

Classification for machine tools

High efficiency workshop

High efficiency Machine tools

Advanced manufacturing process

Carbon footprint (CFP) assessment system of

machining process

Energy efficiency evaluation of machine

tool (energy efficiency grading)

Hard turning (Replacing grinding)

• Focus on

CFP (Carbon Footprint) has historically been defined as "the total set of greenhouse gas (GHG) emissions caused by an organization, event, product or person[1].

More energy efficient and environmentally responsible： • Environmental Initiatives • Education & Awareness • Carbon Reduction • Energy & Resource Efficiency • Local Initiatives

[1]"What is a carbon footprint?". UK Carbon Trust. http://www.carbontrust.co.uk/ solutions/CarbonFootprinting/what_is_a_carbon_footprint. htm. Retrieved 2009-07-24.

6 main GHGs: CO2； CH4；N2O； HFCs；PFCs；SF6

Includes in the two levels : 两个层面的含义：

• Corporate Carbon Footprint 企业碳足迹

• Carbon footprint for a product 产品碳足迹

• 铝制品 • 糖厂

• 可乐生产 • 包装

• 运输 • 库存/冷藏

• 冷藏 • 回收易拉罐 • 垃圾处理/再利用

Carbon footprint for 1 can coca cola: 1罐可口可乐的“碳足迹”

-Company get the carbon emission information for production management 生产过程的碳排放管理

-Consumer make a significant impact on how people make choices about what (or even if) they buy 对消费者给予产品购买指导

Carbon Labeling(碳标签)

Procurement of raw materials

原材料生产

Product manufacturing

产品制造

Distribution & Retail

配送及零售

Consumption, use and

maintenance消费/使用

Disposal & Recycling

处理/回收再利用

Carbon Labeling

Carbon footprint such an important indictor?

traceability 可追溯

measurable可量化

universal 通用/广泛性

policy direction 政策趋势

economic benefit 经济效益

© Fraunhofer IWU

27

Fra

un

ho

fer

IWU

20

12

-04

_ P

z

Consumption of CO2 equivalents of a Golf VI *)

1: CO2 equivalents, incl. methane, laughing gas, cooling medium R132; incl. all materials and manufacturing processes; 150.000 km, incl. fuel supply

*) Prof. Heizmann, VW AG; presentation ICMC, 29.9.2010 Chemnitz

Need for action Operation phase Manufacturing phase

8 % fuels

0%

20%

40%

60%

80%

100%

20 % car manufacturing

70 % car operation

2 % recycling

CO21

∑ 27,4 t CO21

Climate protection

Products for Avoiding GHG

emissions Adapting to climate

change

Reduction for GHG emissions in

Production

Value chain

Advanced Technologies

Maximize economic benefits Energy & Resource Sustainable Development

• Evaluate indicator for greenhouse gas emissions due to energy consumption

• Measured by produced equivalent CO2e • More CO2e emission, larger carbon

footprint, and vice versa.

By Nicks J

Different GHGs (CO2, CH4, N2O, HFCs, PFCs, SF6 have different greenhouse effect . The Carbon dioxide equivalent value is used for CFP assessment by using GWP (Global Warming Potential) to calculate.

iieCO GWPME 2

ECO2e

GWPi

is for CO2e

is for Global Warming Potential

Mi is for gas weight

GHGs GWP （100 year） CO2 1

CH4 25

N2O 298

HFCS 124~14800

PFCS 7390~12200

SF6 22800

GHGs’ GWP

By IPCC

Mechanical processing of machine components is related to the , the carbon footprint of coolant, lubricant, cutting tools, metal chips etc.

CFP of Machining Process

ChipsCutting

toolCoolant

Lubricating oil

Electricity

…

1

m

nToolTotal Machine Coolant Lubricant Chip Others

i i i i i i i

m

C C C C C C C

𝐶𝑖𝑀𝑎𝑐ℎ𝑖𝑛𝑒 --CFP of electricity power consumption

𝐶𝑖Total --Total CFP

……

• CFP is defined as Carbon footprint per kilogram of a products.

Carbon footprint per kilogram(CFK)

Total

ii

i

CCFK

m im removal material Weight of product

Carbon Labeling

• Mitigation of climate change • To reduce greenhouse gas (Greenhouse

Gases, GHG) emissions • Promote low-carbon emission technologies

U.K. America Korea Canada

Japan France North America Chinese Taiwan

CFK is main index for

Carbon Labeling

单位功效碳足迹

噪声

粉尘浓度

油雾浓度

刺激性气味

2kg-CO /kg/cycle（ ）

3mg/m /cycle（ ）3mg/m /cycle（ ）

××

dB/ cycle（ ）

1

2

3

4

5

机床能效属性标识Re & En Label for Machine Tools

生产者名称 ___________________________

规 格 型 号 ___________________________

依据国家标准： GB xxxx.xxxx

好

中等

差

××

××

××

××

Source: Lange

材料利用率 加工方法 能源消耗

铸造

烧结

冷温压力加工

锻造加工

切削加工

Different Manufacturing → Different CFP

High efficiency workshop

low-carbon process

Manufacture process Research objectives:

•Clearly analyzing resource consumption in manufacturing process.

•Systematic evaluation of the low-carbon properties of manufacturing resources,

carbon footprint modeling

•The allocation of resources for the assessment of low-carbon manufacturing

process planning and optimization

Resource consumption

analysis

High efficiency and low carbon manufacturing resources evaluation and optimization

low-carbon evaluation

Manufacturing Resource Optimization for low-carbon and

efficient

Evaluation, control and optimization under constraint of resources and ecological environment during the production

process

Resource consumption analysis

Ecological constraints

Optimize the allocation of resources

Research content:

Analysis of resource consumption in

manufacturing process

Systematic evaluating low-carbon properties

of resources

Resources optimization

High efficiency & low-carbon manufacturing

low-carbon Grading

High efficiency & low carbon workshop

Carbon footprint (CFP) assessment system of machining process

Indicators for data collection 指标数据的采集 (1) indirect data directly after acquisition or acquisition through conversion and corresponding relationships; 间接数据直接采集或采集后通过相应关系进行换算 (2) according to the standard collection methods and requirements gathering, selection or direct experience; 按照国家标准的采集方法和要求进行采集，或者直接选用经验值 (3) using field observation on qualitative description. 采用现场观察进行定性描述

Composite index

Quantitative indicators

Resources Consumption

Waste disposal

Utilization

Qualitative indicators

Environmental management system

Auditing on energy-efficient production

Waste disposal system

Cost-based

indicators

Efficiency

indicators

Ecological

impact

Carbon emissions

Production process assessment

source: Daimler AG, PPA/GSU

In production process, the GHG emissions exist in each process, which includes direct discharge(DD), optional discharge(OD) and indirect discharge(ID).

Qualified products

Raw materials

Auxiliary materials

(lubricants, cutting

fluids...)

Energy (electricity,

heat...)

Others

Optimization technology

Input Disposals output

Output

Liquid wastes

Others

Dust

Carbon footprint

Other discharges

CH4

CO2

Process 1

Process 2

Process i

I1

I2

Ii

Process nIn

O1

O2

Oi

On

Transportation/

inventory Status 1

…

Status i

Production process for products

Production control

C1

Disposal Weights

C2

…

P1

P2

...

Pm

ωC1

ωC2

ωP1

ωP2

...

ωPm

…

Solid wastes

Gas C ω

…

Transportation/

inventory

Transportation/

inventory

ci

n

iiCC

1

Pi

m

iiPP

1

Ci (i=1,2,…,n) -- optional CO2e emissions induced from the use of materials/chemicals in an assessed process; ωCi --emission factor of the nth type of material. Pi --the discharge unrelated to carbon footprint(such as noise, dusts, etc.) ωPi --the emission factor of the mth type of material.

CFP Assessment Model for manufacturing system

Metal Cutting process (based on CFP)

1

m

nToolTotal Machine Coolant Lubricant Chip Others

i i i i i i i

m

C C C C C C C

Ci

machine = EFe´ (E

servomotor+ E

spindlemotor+E

coolingsystem+ E

compressor

+Ecoolantpump

+ Echipconveyor

+ EATC

+ Etoolmagazine

+ Estand-by

)

*coolantcprod cdisp coolant coolant water water water

update

{( ) ( ) ( )}coolant

i

tC EF EF V V EF V V

t

lubricant

spindlelub slidewaylubiC C C

{( ) }( 1)

prodtool

toolprod tooldisp tool re re

toolife re

tC EF EF m N C

t N

workpiece product density chip( )chip

iC V V EF

The total CO2e emissions of each product can be calculated out

Production process evaluation system

Resources

consumption

Ecological

influences

MaterialCutting

toolCoolant

Lubricating

oil Electricity

Pungent

odorOil mist Dust Noisy Security Others

Goal

Criterial

Machining Strategy

AlternativesMachine tool 1 Machine tool 2 Machine tool n. . .

CFKComprehensive index

system

• CFK is the main efficiency evaluation index of electrical energy , resource and and environmental emissions.

Carbon footprint per kilogram(CFK)

Total

ii

i

CCFK

m im removal material Weight of product

By AHP evaluation method

• A milling evaluation case

Workpiece & tool path

100±0.14

10

0±

0.1

4

37

±0

.1

42

28

48

50±0.1

6

5

17

.5

R6

Tool diameter 10mm with 30 °helix angle, XK714 CNC mill

Name Unit Value

electricity kg-CO2/kWh 0.5482

Coolant producing kg-CO2/L 2.85

Coolant processing kg-CO2/L 0.189

Dilution (water) kg-CO2/L 0.189

Spindle and guideway

lubricant producing kg-CO2/L 2.85

Spindle and guideway

lubricant processing kg-CO2/L 0.189

Tool producing kg-CO2/kg 24

Tool processing kg-CO2/kg 24

Regrinding kg-CO2/time 2.47

Chips processing kg-CO2/kg 2.47

CFP factor

Name Data Grade

Spindle & servo motor(g-CO2) 3.721

Auxiliary electricity(g-CO2) 75.895

Lubricant (g-CO2) 0.065

Chip (g-CO2) 10.99 ―

Tool (g-CO2) 12.361

Coolant (g-CO2) 1.747

Total CFP (g-CO2) 104.779

CFK（kg-CO2/kg） 0.606 3

CFK Noise Dust Mist Irritant gas Safety

CFK 1 5 3 3 3 2

Noise 1/5 1 1/3 1/3 1/3 1/4

Dust 1/3 3 1 1 1 1/3

Mist 1/3 3 1 1 1 1/3

Irritant gas 1/3 3 1 1 1 1/3

Safety 1/2 4 3 3 3 1

Carbon emissions

Manufacturing resources configuration judge matrix

133342/1

3/111133/1

3/111133/1

3/111133/1

4/12/12/12/115/1

233351

A

TW )262.0,112.0,112.0,112.0,058.0,343.0(

CFK weight 2.079

Grade 1 2 3 4 5

Degree Very

slight

sligh

t

Med

ium

Seve

re

Very

Severe

Weight 0-1 1-2 2-3 3-4 4-5

Weight calculating

Resource environment property Grading

High efficiency Machine tools

Research objectives:

•Machine tool energy consumption monitoring platform •Efficiency evaluation sample design, evaluation methods and energy efficiency rating. •High Efficient manufacturing process optimization •High Efficient machine tool design for high performance

Research content:

Energy efficiency evaluation of machine tool (energy efficiency grading)

Environment Evlauation

Dust

Oil mist

Irritant gases

Noise

Po

we

r Effice

ncy

单位功效碳足迹

噪声

粉尘浓度

油雾浓度

刺激性气味

2kg-CO /kg/cycle（ ）

3mg/m /cycle（ ）3mg/m /cycle（ ）

0.602

76

0.86

2.73

3

dB/ cycle（ ）

1

2

3

4

5

机床资源环境属性标识Re & En Label for Machine Tools

生产者名称 日本大隈株式会社 社

规 格 型号 1 MB-46VA立式加工中心 1

依据国家标准： GB xxxx.xxxx

好

中等

差

3级

Energy, Raw material(Semi -

finished products),Auxiliary

materials(coolant, Lubricants)

Solid, liquid gas Waste

Environmental Factors

Air heat exchange

Machine tool structural modeling

Evaluation BoundaryEvaluation objective Process Test Workpiece

Signal acquisition and analysisResults Evaluation

Source: Prof. Abele, Prof. Heisel, Prof. Verl

CFK Evaluation

Difficulties:

•CFK test Workpiece •The appropriate cutting parameters

单位功效碳足迹

噪声

粉尘浓度

油雾浓度

刺激性气味

2kg-CO /kg/cycle（ ）

3mg/m /cycle（ ）3mg/m /cycle（ ）

××

dB/ cycle（ ）

1

2

3

4

5

机床能效属性标识Re & En Label for Machine Tools

生产者名称 ___________________________

规 格 型 号 ___________________________

依据国家标准： GB xxxx.xxxx

好

中等

差

××

××

××

××

Power efficiency

Process parametersoptimization

Machine tools innovation

Test Workpiece

Reasonable design,

suitable for machine tool

Rough/finishingprocess,

combination of experimental parameters

Weights of each process

Energy comsumption

Dimension, surface quality

Process MeasureEnergy

efficiency

Noise,Dust,Oil mist etc

CNC lathe energy efficiency evaluation

Power efficiency : The value of power for material removal divided by the total machine tool power

High efficiency Machine tools

Source：Nancy Diaz

CNC lathe energy efficiency evaluation

•Usually, with restrict parameters, the cutting power is proportion to the MRR(material removal rate), but the energy is not. •With different cutting parameters, like rough and finish process, the ratio of power and MRR is different.

Characteristics of rough and finish lathe machining • Within a certain range: cutting power efficiency

increases with increasing of f, ap and Vc. • f, ap, Vc are limited to the machine rigidity, processing

quality, tools and other factors, so they can not be increased without limit.

• Evaluation of the energy efficiency of the lathe cutting power should be limited to the scope of the process parameters. Evaluate energy efficiency respectively

during roughing or finishing process.

Rough ，finish or both？ The exact process parameters? The weight of each process ？

Source：Nancy Diaz

Lathe cutting example SKF3 steel pipe with 140mm OD 80ID

• Rough：Spindle vary at 40% to70%，(Ra<6.3)

• Set ap2.25~0.275； f 0.3375~0.4125； Vc373.5~415

No ap(mm) f(mm/r) vc(m/min) Total power(w) Cutting power(w) efficiency

1 2.25 0.3375 373.5 14550 8703.377 59.82%

2 2.25 0.375 415 17250 10603.78 61.47%

3 2.25 0.4125 456.5 20150 12600.15 62.53%

4 2.5 0.3375 415 17300 10690.12 61.79%

5 2.5 0.375 456.5 20350 12831.24 63.05%

6 2.5 0.4125 373.5 18700 11623.65 62.16%

7 2.75 0.3375 456.5 20450 12297.7 60.14%

8 2.75 0.375 373.5 18700 12199.56 65.24%

9 2.75 0.4125 415 22200 14237.24 64.13% • Finish (Ra<3.2)

• set ap0.3~0.5； f 0.1~0.3； Vc 370~475

ap(mm) f(mm/r) vc(m/min) Total power(w) Cutting power(w) efficiency

1 0.3 0.1 370 2540 778.75441 30.66%

2 0.3 0.2 475 3580 1426.852 39.86%

3 0.3 0.3 555 4740 2204.4604 46.51%

4 0.4 0.1 475 3270 1264.8571 38.68%

5 0.4 0.2 555 4550 2109.7439 46.37%

6 0.4 0.3 370 4150 1713.3343 41.29%

7 0.5 0.1 555 4160 1848.9585 44.45%

8 0.5 0.2 370 3860 1226.267 31.77%

9 0.5 0.3 475 5420 2534.5056 46.76%

Rough efficiency: 62.26% ； Finish efficiency : 40.70%； Set weight of rough and finish is 0.8 and 0.2，then the overall efficiency is57.95%

Energy efficiency test sample

Workpiece machining→ Power status → Efficiency of power → Continuous testing → efficiency of energy

As shown in this test sample, the rough process parameter ap=2.5，Vc=415，f=0.375, finish process parameter ap=0.4， Vc=475, f=0.2， efficiency of energy ：37.8%

Grade 1 2 3 4 5

Degree >50

%

40~5

0%

30~4

0%

20~3

0%

<50

%

Resource environment property Grading

机床能效

机床额定功率

37.8%

30Kw

1

2

3

4

5

机床能效属性标识Re & En Label for Machine Tools

生产者名称 ___________________________

规 格 型 号 ___________________________

依据国家标准： GB xxxx.xxxx

好

中等

差

3级

Research objectives:

• Comparing with traditional lathe, research differences of hard-turning lathe process parameters.

• Optimize process parameters for high performance machining. • Comparing with the grinder, hard-turning energy efficiency.

Advanced manufacturing process

Hard turning (Replacing grinding)

Research content:

Optimized process parameters

hard-turning energy efficiency

Specimens

Pipe，pipe with one slot，pipe

with 4 slots.

Orthogonal test parameters（Finish cutting）

Weights of each process

Tool wear

Dimension, surface quality

Cutting MeasureComprehensive evaluation

Energy consumption

High rigidity lathe

CY-CTC4050 high stiffness slant bed CNC lathe has excellent hard cutting performance, it can machine HRC 62 hardness workpiece. Closed loop control, the maximum spindle speed 4000 rpm, with high rigidity, high accuracy, high dynamic response, and efficient.

Conclusions •Comparing with traditional lathe, the hard-turning machine has a good rigidity, can cut HRC56~62 hardness workpiece.

•Using appropriate process parameters , it can gain rather well dimension precision, the roughness can reach Ra<0.2.

•No burn phenomenon

•Energy consumption lower than same accuracy grinding machine

•Slot benefit chip breakage, the surface quality is better than no slot.

•Smaller feedrate helps improve surface quality.

Ra=0.4 no slot Vc=240, f=0.15, ap=0.3

Ra=0.35 one slot Vc=120, f=0.15, ap=0.2

Ra=0.35 one slot Vc=120, f=0.15, ap=0.2

Summary and Outlook

单位功效碳足迹

噪声

粉尘浓度

油雾浓度

刺激性气味

××

1

2

3

4

5

机械工艺碳排放属性标识Carbon Emissions Label for

Machining Product

生产者名称 ___________________________

规 格 型 号 ___________________________

依据国家标准： GB xxxx. xxxx

碳排放影响小

××

××

××

××

碳排放影响大

1

工艺过程产生

碳足迹

碳足迹量化

（CFP）

单位功效碳足迹

（CFK）

碳足迹分级评价

（评价碳效益）

...

CFK

单位：kgCO2/kg

加工工件

Carbon Footprint

China