Abstract
An energy-saving and environment-friendly manufacturing process is essential to address the large energy and resource consumption in manufacturing. Sheet metal forming is an important manufacturing process and is widely used in automobile and aviation industries. Sheet metal forming is also an energy-intensive process in manufacturing and consumes a large amount of energy because of its low energy efficiency. In this study, a comprehensive energy-saving method was proposed to reduce the energy consumption and improve the energy efficiency of sheet metal forming. On the basis of the developed process energy models of sheet metal forming, a novel process optimization method was proposed to reduce the process energy consumption of metal forming parts without sacrificing their forming quality. The proposed process optimization method was melded with previous energy-matching control method of forming equipment to further decrease the energy consumption in sheet metal forming. The comprehensive energy-saving method for sheet metal forming was integrally applied to a stamping process chain. Results show that the energy consumption can be decreased by 37% compared with the original stamping process chain. Therefore, the proposed method shows significant energy-saving potential.
Similar content being viewed by others
References
Manufacturing technology development strategy in China. (2015) http://news.makepolo.com/165459.html. (accessed on June 2015)
Liu C, Cai W, Jia S, Zhang M, Guo H, Hu L, Jiang Z (2018) Emergy-based evaluation and improvement for sustainable manufacturing systems considering resource efficiency and environment performance. Energy Convers Manag 177:176–189
National Bureau of Statistics of the People’s Republic of China. (2017) http://www.stats.gov.cn/tjsj/ndsj/2017/indexch.htm
EIA, Annual Energy Review (2011) http://www.eia.gov/totalenergy/data/annual/index.cfm
Gao M (2017) Research on low carbon and energy saving optimization method for stamping forming process. Hefei University of Technology, Hefei
Fu X (2012) Study on formability and forming mechanism of sheet metals in variable forming speed/forming loading stamping process. Huazhong University of Science and Technology, Wuhan
Worldwide automobile production from 2000 to 2016 (2017) https://www.statista.com/statistics/262747/worldwide-automobile-production-since-2000/. (Accessed: 20.12.2017)
Zhao K, Liu Z, Yu S, Li X, Huang H, Li B (2015) Analytical energy dissipation in large and medium-sized hydraulic press. J Clean Prod 103:908–915
Fan H, Wang J, Liu K (2009) Research on energy-saving technology of four workshops in vehicle manufacturing enterprises. Auto Eng (8):54–57
Ingarao G, Ambrogio G, Gagliardi F, Di Lorenzo R (2012) A sustainability point of view on sheet metal forming operations: material wasting and energy consumption in incremental forming and stamping processes. J Clean Prod 29-30:255–268
Gao M, Huang H, Li X, Liu Z (2016) Carbon emission analysis and reduction for stamping process chain. Int J Adv Manuf Technol 91(1–4):667–678
Gao M, Huang H, Wang Q, Liu Z, Li X (2018) Energy consumption analysis on sheet metal forming: focusing on the deep drawing processes. Int J Adv Manuf Technol 96(9–12):3893–3907
Cooper DR, Rossie KE, Gutowski TG (2017) The energy requirements and environmental impacts of sheet metal forming: an analysis of five forming processes. J Mater Process Technol 244:116–135
Kitayama S, Yamada S (2017) Simultaneous optimization of blank shape and variable blank holder force of front side member manufacturing by deep drawing. Int J Adv Manuf Technol 91(1–4):1381–1390
Tamai Y, Inazumi T, Manabe KI (2016) FE forming analysis with nonlinear friction coefficient model considering contact pressure, sliding velocity and sliding length. J Mater Process Technol 227(636):161–168
Jia C, Green DE, Golovashchenko SF (2017) Formability enhancement of DP600 steel sheets in electro-hydraulic die forming. J Mater Process Technol 244:178–189
Karbasian H, Tekkaya AE (2010) A review on hot stamping. J Mater Process Technol 210(15):2103–2118
Merklein M, Wieland M, Lechner M, Bruschi S, Ghiotti A (2016) Hot stamping of boron steel sheets with tailored properties: a review. J Mater Process Technol 228:11–24
Quan Z, Long Q, Zhang J (2014) Review of energy efficient direct pump controlled cylinder electro-hydraulic technology. Renew Sustain Energy Rev 35:336–346
Behrens BA, Bouguecha A, Krimm R, Teichrib S, Nitschke T (2016) Energy-efficient drive concepts in metal-forming production. Procedia Cirp 50:707–712
Li L, Huang H, Zhao F, Sutherland JW, Liu Z (2017) An energy-saving method by balancing the load of operations for hydraulic press. IEEE/ASME Trans Mechatron 22(6):2673–2683
Li L, Huang H, Zhao F, Triebe MJ, Liu Z (2017) Analysis of a novel energy-efficient system with double-actuator for hydraulic press. Mechatronics 47:77–87
Li L, Huang H, Zhao F, Liu Z (2017) Operation scheduling of multi-hydraulic press system for energy consumption reduction. J Clean Prod 165:1407–1419
Li L, Huang H, Zhao F, Liu ZF (2016) A coordinate method applied to partitioned energy-saving control for grouped hydraulic presses. J Manuf Syst 41:102–110
Ho TH, Ahn KK (2012) Design and control of a closed-loop hydraulic energy-regenerative system. Autom Constr 22(4):444–458
Lin T, Wang Q (2012) Hydraulic accumulator-motor-generator energy regeneration system for a hybrid hydraulic excavator. Chin J Mech Eng 25(6):1121–1129
Wang T, Wang Q, Lin T (2013) Improvement of boom control performance for hybrid hydraulic excavator with potential energy recovery. Autom Constr 30(4):161–169
Gao M, Huang H, Li X, Liu Z (2016) A novel method to quickly acquire the energy efficiency for piston pumps. J Dyn Syst Meas Control- Trans ASME 138(10):101004–101012
Gao M, Li X, Huang H, Liu Z, Li L, Zhou D (2016) Energy-saving methods for hydraulic presses based on energy dissipation analysis. Procedia Cirp 48:331–335
Gao M, Liu Z, Wang Y (2016) A novel method to quick acquire the energy efficiency for the three-phase induction motors. China Mech Eng 27(13):1755–1759
Ying L (2013) Research and application on key process experiment of high strength steel for hot forming. Dalian University of Technology, Dalian
Lavault C Plastic bending: theory and applications. Prentice Hall, New Jersey, pp 587–588
Zhou J, Wang B, Lin J, Fu L (2013) Optimization of an aluminum alloy anti-collision side beam hot stamping process using a multi-objective genetic algorithm. Arch Civil Mech Eng 13(3):401–411
Srinivas N, Deb K (2014) Multiobjective optimization using nondominated sorting in genetic algorithms. Evol Comput 2(3):221–248
Deb K, Agrawal S, Pratap A, Meyarivan T (2000) A fast elitist non-dominated sorting genetic algorithm for multi-objective optimization: NSGA-II. International Conference on Parallel Problem Solving From Nature, Springer-Verlag, pp 849–858
Li L, Huang H, Liu Z, Li X, Triebe MJ, Zhao F (2016) An energy-saving method to solve the mismatch between installed and demanded power in hydraulic press. J Clean Prod 139:636–645
Ko DC, Cha SH, Lee SK, Lee CJ, Kim BM (2010) Application of a feasible formability diagram for the effective design in stamping processes of automotive panels. Mater Des 31(3):1262–1275
Kumar Y, Das B, Sharma J (2006) Service restoration in distribution system using non-dominated sorting genetic algorithm. Electr Power Syst Res 76(9):768–777
Funding
This work was financially supported by the Natural Science Research Project in Universities of Anhui Province in China (KJ2018A0451), Suzhou Science and Technology Project (SZ2017GG28), Suzhou College Professor (Doctor) Scientific Research Foundation Project (2017JB03), and Suzhou Engineering Research Center for Collaborative Innovation of Mechanical Equipment (SZ2017ZX07).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Gao, M., Wang, Q., Li, L. et al. Comprehensive energy-saving method for sheet metal forming. Int J Adv Manuf Technol 104, 2273–2285 (2019). https://doi.org/10.1007/s00170-019-04022-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-04022-4