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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]
+ Show Author Affiliations
  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 Laboratory (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE; National Natural Science Foundation of China (NSFC)
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.
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He, Keyan, Tang, Renzhong, Jin, Mingzhou, Cao, Yanlong, & Nimbalkar, Sachin U. Energy modeling and efficiency analysis of aluminum die-casting processes. United States. https://doi.org/10.1007/s12053-018-9730-9
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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. https://doi.org/10.1007/s12053-018-9730-9. https://www.osti.gov/servlets/purl/1513409.
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@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 = {Fri Sep 21 00:00:00 EDT 2018},
month = {Fri Sep 21 00:00:00 EDT 2018}
}
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Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1007/s12053-018-9730-9
Copyright Statement
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Citation Metrics:
Cited by: 11 works
Citation information provided by
Web of Science

Figures / Tables:

Fig. 1 Fig. 1: Structure of the data acquisition and analysis system
All figures and tables (13 total)
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Works referenced in this record:

Impact of energy efficiency on computer numerically controlled machining
journal, November 2009

  • Anderberg, S. E.; Kara, S.; Beno, T.
  • Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 224, Issue 4
  • DOI: 10.1243/09544054JEM1712

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

A Computer-Aided System for Sustainability Analysis for the Die-Casting Process
conference, July 2013

  • Singh, Princepal; Madan, Jatinder; Singh, Amrik
  • ASME 2012 International Manufacturing Science and Engineering Conference collocated with the 40th North American Manufacturing Research Conference and in participation with the International Conference on Tribology Materials and Processing
  • DOI: 10.1115/MSEC2012-7303

The Challenges for Energy Efficient Casting Processes
journal, January 2016

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

Energy and Resource Efficiency in Aluminium Die Casting
book, January 2016

Sustainability Characterization for Die Casting Process
conference, February 2014

  • Watkins, Megan F.; Mani, Mahesh; Lyons, Kevin W.
  • ASME 2013 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, Volume 2A: 33rd Computers and Information in Engineering Conference
  • DOI: 10.1115/DETC2013-12634

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

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

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

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

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

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

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

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

An Environmental Analysis of Injection Molding
conference, January 2006

  • Thiriez, A.; Gutowski, T.
  • Proceedings of the 2006 IEEE International Symposium on Electronics and the Environment, 2006.
  • DOI: 10.1109/ISEE.2006.1650060

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

  • 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

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

A Material and Energy Flow Oriented Method for Enhancing Energy and Resource Efficiency in Aluminium Foundries
book, January 2012

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

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

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    Works referencing / citing this record:

    Energy and Resource Efficiency in Aluminium Die Casting
    book, January 2016

    A Material and Energy Flow Oriented Method for Enhancing Energy and Resource Efficiency in Aluminium Foundries
    book, January 2012

    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

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      Figures / Tables found in this record:

      Fig. 1 (p. 5)figure
      Fig. 2 (p. 5)figure
      Table 1 (p. 5)table
      Fig. 3 (p. 6)figure
      Table 2 (p. 7)table
      Table 3 (p. 8)table
      Table 4 (p. 8)table
      Fig. 4 (p. 9)figure
      Fig. 5 (p. 9)figure
      Table 5 (p. 11)table
      Fig. 6 (p. 12)figure
      Fig. 7 (p. 13)figure
      Table 6 (p. 13)table
        [ × clear filter / sort ]
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