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Title: Energy modeling and efficiency analysis of aluminum die-casting processes

Abstract

Energy modeling and efficiency analysis are considered the foundation of manufacturing process optimization to improve quality and efficiency and reduce energy consumption and carbon emissions during aluminum die-casting processes. Our report introduced an energy modeling method to connect gas and electric energy consumption with production rate of aluminum die-casting processes based on data collected at workshops with various combination of machines and products. The detailed modeling process involved the development of a data-acquiring system and the comparison of various kinds of nonlinear regression methods. The resulting models were confirmed with actual production data and were also used to improve production scheduling. Furthermore, it was found that if the modeling results are reasonably used and production is accordingly well-scheduled, 10 to 15% of energy savings could be realized without sacrificing profits.

Authors:
 [1];  [1]; ORCiD logo [2];  [1]; ORCiD logo [3]
  1. Zhejiang Univ., Hangzhou (China)
  2. Zhejiang Univ., Hangzhou (China); The Univ. of Tennessee, Knoxville, TN (United States)
  3. The Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE; National Natural Science Foundation of China (NNSFC)
OSTI Identifier:
1513409
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Energy Efficiency
Additional Journal Information:
Journal Volume: 12; Journal Issue: 5; Journal ID: ISSN 1570-646X
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; Aluminum die-casting process; Energy consumption modeling; Data acquisition; Energy efficiency analysis

Citation Formats

He, Keyan, Tang, Renzhong, Jin, Mingzhou, Cao, Yanlong, and Nimbalkar, Sachin U. Energy modeling and efficiency analysis of aluminum die-casting processes. United States: N. p., 2018. Web. doi:10.1007/s12053-018-9730-9.
He, Keyan, Tang, Renzhong, Jin, Mingzhou, Cao, Yanlong, & Nimbalkar, Sachin U. Energy modeling and efficiency analysis of aluminum die-casting processes. United States. doi:10.1007/s12053-018-9730-9.
He, Keyan, Tang, Renzhong, Jin, Mingzhou, Cao, Yanlong, and Nimbalkar, Sachin U. Fri . "Energy modeling and efficiency analysis of aluminum die-casting processes". United States. doi:10.1007/s12053-018-9730-9. https://www.osti.gov/servlets/purl/1513409.
@article{osti_1513409,
title = {Energy modeling and efficiency analysis of aluminum die-casting processes},
author = {He, Keyan and Tang, Renzhong and Jin, Mingzhou and Cao, Yanlong and Nimbalkar, Sachin U.},
abstractNote = {Energy modeling and efficiency analysis are considered the foundation of manufacturing process optimization to improve quality and efficiency and reduce energy consumption and carbon emissions during aluminum die-casting processes. Our report introduced an energy modeling method to connect gas and electric energy consumption with production rate of aluminum die-casting processes based on data collected at workshops with various combination of machines and products. The detailed modeling process involved the development of a data-acquiring system and the comparison of various kinds of nonlinear regression methods. The resulting models were confirmed with actual production data and were also used to improve production scheduling. Furthermore, it was found that if the modeling results are reasonably used and production is accordingly well-scheduled, 10 to 15% of energy savings could be realized without sacrificing profits.},
doi = {10.1007/s12053-018-9730-9},
journal = {Energy Efficiency},
number = 5,
volume = 12,
place = {United States},
year = {2018},
month = {9}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Figures / Tables:

Fig. 1 Fig. 1: Structure of the data acquisition and analysis system

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Works referenced in this record:

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Improvements in energy consumption and environmental impact by novel single shot melting process for casting
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A carbon efficiency approach for life-cycle carbon emission characteristics of machine tools
journal, December 2012


LCA as a decision support tool for evaluation of best available techniques (BATs) for cleaner production of iron casting
journal, October 2015


Evaluation on models of calculating energy consumption in metal cutting processes: a case of external turning process
journal, July 2015

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  • The International Journal of Advanced Manufacturing Technology, Vol. 82, Issue 9-12
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Environmental evaluation of grey cast iron via life cycle assessment
journal, April 2017


Simulation Based Studies of Energy Saving Measures in the Aluminum Tool and Die Casting Industry
journal, November 2016


Energy efficiency opportunities in the production process of cast iron foundries: An experience in Italy
journal, November 2015


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journal, September 2017


    Works referencing / citing this record:

    Evaluation on models of calculating energy consumption in metal cutting processes: a case of external turning process
    journal, July 2015

    • Zhong, Qianqian; Tang, Renzhong; Lv, Jingxiang
    • The International Journal of Advanced Manufacturing Technology, Vol. 82, Issue 9-12
    • DOI: 10.1007/s00170-015-7477-4

    The worldwide aluminum economy: The current state of the industry
    journal, November 2007


    Energy efficiency opportunities in the production process of cast iron foundries: An experience in Italy
    journal, November 2015


    On melting characteristics of bulk Al-7039 alloy during in-situ microwave casting
    journal, January 2017


    Dealing with barriers to energy efficiency and SMEs: Some empirical evidences
    journal, January 2012


    Pareto fronts of machining parameters for trade-off among energy consumption, cutting force and processing time
    journal, March 2017

    • He, Keyan; Tang, Renzhong; Jin, Mingzhou
    • International Journal of Production Economics, Vol. 185
    • DOI: 10.1016/j.ijpe.2016.12.012

    A carbon efficiency approach for life-cycle carbon emission characteristics of machine tools
    journal, December 2012


    Barriers to industrial energy efficiency in foundries: a European comparison
    journal, February 2013


    LCA as a decision support tool for evaluation of best available techniques (BATs) for cleaner production of iron casting
    journal, October 2015


    Improvements in energy consumption and environmental impact by novel single shot melting process for casting
    journal, November 2016


    Environmental evaluation of grey cast iron via life cycle assessment
    journal, April 2017


    The Challenges for Energy Efficient Casting Processes
    journal, January 2016


    The Development of a Tool to Promote Sustainability in Casting Processes
    journal, January 2016


    Simulation Based Energy and Resource Efficient Casting Process Chain Selection: A Case Study
    journal, January 2017


    Analysis of energy savings potential of China's nonferrous metals industry
    journal, February 2017


    Energy efficiency opportunities in the service plants of cast iron foundries in Italy
    journal, May 2016

    • Lazzarin, Renato M.; Noro, Marco
    • International Journal of Low-Carbon Technologies
    • DOI: 10.1093/ijlct/ctw011

    Sustainable Modeling of Die-Casting Processes through Matlab
    journal, September 2017