scholarly journals A Systematic Methodology for Accurate Design-Stage Estimation of Energy Consumption for Injection Molded Parts

2010 ◽  
Author(s):  
Alexander Weissman ◽  
Arvind Ananthanarayanan ◽  
Satyandra K. Gupta ◽  
Ram D. Sriram
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Product Design ◽  
Flow Simulation ◽  
Setup Time ◽  
Analytical Models ◽  
Design Stage ◽  
Limited Information ◽  
Energy Estimation ◽  
Time Required

Today’s ubiquitous use of plastics in product design and manufacturing presents significant environmental and human health challenges. Injection molding, one of the most commonly used processes for making plastic products, consumes a significant amount of energy. A methodology for accurately estimating the energy consumed to injection-mold a part would enable environmentally conscious decision making during the product design. Unfortunately, only limited information is available at the design stage. Therefore, accurately estimating energy consumption before the part has gone into production can be challenging. In this paper, we describe a methodology for energy estimation that works with the limited amount of data available during the design stage, namely the CAD model of the part, the material name, and the production requirements. The methodology uses this data to estimate the parameters of the runner system and an appropriately sized molding machine. It then uses these estimates to compute the machine setup time and the cycle time required for the injection molding operation. This is done by appropriately abstracting information available from the mold flow simulation tools and analytical models that are traditionally used during the manufacturing stage. These times are then multiplied by the power consumed by the appropriately sized machine during each stage of the molding cycle to compute the estimated energy consumption per part.

Machine-Specific Estimation of Milling Energy Consumption in Detailed Design

2021 ◽  
pp. 1-24
Author(s):  
Till Boettjer ◽  
Johan Krogshave ◽  
Devarajan Ramanujan
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Design Stage ◽  
Total Energy Consumption ◽  
Estimation Errors ◽  
Workpiece Material ◽  
Detailed Design ◽  
Energy Estimation ◽  
Unit Process

Abstract Manufacturing is a significant contributor to global greenhouse gas emissions and there is an urgent need to reduce the energy consumption of production processes. An important step towards this goal is proactively estimating process energy consumption at the detailed design stage. This is a challenging task as variabilities in factors such as process specifications, machine tool architecture, and workpiece geometry can significantly reduce the accuracy of the estimated energy consumption. This paper discusses a methodology for machine-specific energy estimation in milling processes at the detailed design stage based on the unit process life cycle inventory (UPLCI) model. We develop an adjusted UPLCI model that includes adjustment factors for uncertainties in machine tool specifications and the specific cutting energy of a workpiece material. To validate the adjusted UPLCI model, we conducted a case study that measured the energy consumption for machining three parts made of Aluminum 6082 on two separate three-axis vertical milling machines, a Chevalier QP2040-L and a Leadwell MCV-OP. Results show that the UPLCI model consistently overestimated the total energy consumption for machining the three validation parts across both machine tools. We also found the adjusted UPLCI model significantly reduced the estimation errors for the same tests for both machine tools.

Selecting a Design-Stage Energy Estimation Approach for Manufacturing Processes

2011 ◽  
Author(s):  
Alexander Weissman ◽  
Satyandra K. Gupta
Keyword(s):  
Energy Consumption ◽  
Point Of View ◽  
Critical Parameters ◽  
Design Stage ◽  
Design Parameters ◽  
Manufacturing Processes ◽  
Design Work ◽  
Energy Estimation ◽  
Energy Consuming ◽  
Facility Level

Manufacturing is an energy-intensive process which could account for significant energy consumption worldwide. Reducing energy consumption on a product level, in addition to a process or facility level, is being seen as a more worthwhile endeavor in light of rising energy costs and environmental concerns. To accomplish this, it is necessary to consider the role of product design in energy consumption. It is possible to design a product such that its manufacture consumes less energy. However, this requires a good model of energy consumption based on the design parameters. A good model must be detailed enough to yield accurate results, but at the same time simple enough such that it can be applied easily and consistently in day-to-day design work. In this paper, we propose an approach for generating such a model by decomposing the manufacturing process into its energy-consuming components. For each component, the relevant design and manufacturing parameters can be elicited by performing sensitivity analysis through analysis and experimentation. Parameters which do not greatly contribute to variance in energy consumption can be held constant, thus simplifying the model. Thus, the simplest possible model can be derived for a specified level of accuracy. We illustrate that critical parameters from energy point of view can differ greatly from process to process by investigating representative manufacturing processes in four general categories: additive, subtractive, forming, and solidification. Finally, we present a case study for injection molding.

A Novel Pattern for Energy Estimation Framework and Tools to Compute Energy Consumption in Product Life Cycle

2014 ◽  
Vol 14 (1) ◽  
Author(s):  
He Huang ◽  
Gaurav Ameta
Keyword(s):  
Life Cycle ◽  
Energy Consumption ◽  
Product Life Cycle ◽  
Manufacturing Industry ◽  
Design Stage ◽  
Computational Tools ◽  
Energy Estimation ◽  
Product Life ◽  
Domain Specific Knowledge ◽  
Energy Consumptions

Excessive energy consumption has become a worldwide issue in today's design and manufacturing industry. An energy estimation framework that could later be used to integrate with CAD/CAM systems is in demand. This research develops a novel pattern to estimate energy consumptions. The pattern involves a software energy estimation framework and various software energy computational tools. Using this pattern, energy can be calculated by an energy estimation framework which can be attached with diverse energy computational tools. These computational tools can be designed for any purpose to calculate energy consumptions during a product life-cycle and for various manufacturing processes. The framework involved in this pattern features to be domain independent and flexible so that it will be expandable for different manufacturing domains and customizable for users. Details for developing such pattern are presented. Interaction between the framework and its computational tools is also discussed. With help of this pattern, energy estimation framework and energy computational tools can interact smoothly, and the development of computational tools can be extended or expanded for any purpose. Knowledge engineers who exert to integrate knowledge into computer systems can interpret domain-specific knowledge and share their expertise to improve the framework. The framework also assists users who have little knowledge about energy computations to estimate energy consumptions during the design stage, leading to products with reduced energy.

An Overview on Steroids and Microwave Energy in Multi-Component Reactions towards the Synthesis of Novel Hybrid Molecules

2020 ◽  
Vol 17 (8) ◽  
pp. 594-609
Author(s):  
Preetismita Borah ◽  
Vhatkar Dattatraya Shivling ◽  
Bimal Krishna Banik ◽  
Biswa Mohan Sahoo
Keyword(s):  
Energy Consumption ◽  
Multicomponent Reactions ◽  
Biological Activities ◽  
Vital Role ◽  
Microwave Energy ◽  
Biosynthetic Pathways ◽  
Chemical Transformations ◽  
Carbon Carbon Bond ◽  
Hybrid Molecules ◽  
Time Required

In recent years, hybrid systems are gaining considerable attention owing to their various biological applications in drug development. Generally, hybrid molecules are constructed from different molecular entities to generate a new functional molecule with improved biological activities. There already exist a large number of naturally occurring hybrid molecules based on both non-steroid and steroid frameworks synthesized by nature through mixed biosynthetic pathways such as, a) integration of the different biosynthetic pathways or b) Carbon- Carbon bond formation between different components derived through different biosynthetic pathways. Multicomponent reactions are a great way to generate efficient libraries of hybrid compounds with high diversity. Throughout the scientific history, the most common factors developing technologies are less energy consumption and avoiding the use of hazardous reagents. In this case, microwave energy plays a vital role in chemical transformations since it involves two very essential criteria of synthesis, minimizing energy consumption required for heating and time required for the reaction. This review summarizes the use of microwave energy in the synthesis of steroidal and non-steroidal hybrid molecules and the use of multicomponent reactions.

Truck Redesign Case: Simulating the Target Costing Process in a Product Design Environment

2013 ◽  
Vol 29 (1) ◽  
pp. 61-85 ◽  
Author(s):  
Patricia Everaert ◽  
Dan W. Swenson
Keyword(s):  
Product Development ◽  
Product Design ◽  
Goal Setting ◽  
Cost Reduction ◽  
Data Availability ◽  
Design Stage ◽  
Target Costing ◽  
Design Environment ◽  
Goal Setting Theory ◽  
Setting Theory

ABSTRACT This active learning exercise simulates the target costing process and demonstrates how a management theory (goal setting theory) is relevant to a business improvement initiative (target costing). As part of the target costing simulation, student participants work in teams to address a business issue (product development) that moves across functional boundaries. The simulation begins with students learning how to assemble a model truck and calculate its product cost using activity-based costing. Students are then divided into teams and instructed to reduce the truck's cost through a redesign exercise, subject to certain customer requirements and quality constraints. Typically, the teams achieve cost reduction by eliminating unnecessary parts, by using less expensive parts, and by using less part variety. This exercise provides a unique opportunity for students to actively participate in a redesign exercise. It results in student teams creating a wide variety of truck designs with vastly different product costs. The case ends by having a discussion about target costing, goal setting theory, and the implications of the target costing simulation. This simulation contains a number of specific learning objectives. First, students learn how the greatest opportunity for cost reduction occurs during the product design stage of the product development cycle. Second, students see firsthand how design-change decisions affect a product's costs, and the role of the cost information in guiding those decisions. Third, students experience the cross-functional interaction that occurs between sales and marketing, design engineering, and accounting during product development. Finally, this exercise helps students understand the concept of target costing. The simulation is appropriate for undergraduate or graduate management accounting classes. Data Availability:  For more information about this case, contact the first author at [email protected].

scholarly journals Review on Urban Heat Island in China: Methods, Its Impact on Buildings Energy Demand and Mitigation Strategies

2021 ◽  
Vol 13 (2) ◽  
pp. 762
Author(s):  
Liu Tian ◽  
Yongcai Li ◽  
Jun Lu ◽  
Jue Wang
Keyword(s):  
Energy Consumption ◽  
Urban Heat Island ◽  
Building Energy ◽  
Design Stage ◽  
Heat Island ◽  
Building Energy Consumption ◽  
Rapid Urbanization ◽  
Substantial Impact ◽  
Urban Heat ◽  
The Impact

High population density, dense high-rise buildings, and impervious pavements increase the vulnerability of cities, which aggravate the urban climate environment characterized by the urban heat island (UHI) effect. Cities in China provide unique information on the UHI phenomenon because they have experienced rapid urbanization and dramatic economic development, which have had a great influence on the climate in recent decades. This paper provides a review of recent research on the methods and impacts of UHI on building energy consumption, and the practical techniques that can be used to mitigate the adverse effects of UHI in China. The impact of UHI on building energy consumption depends largely on the local microclimate, the urban area features where the building is located, and the type and characteristics of the building. In the urban areas dominated by air conditioning, UHI could result in an approximately 10–16% increase in cooling energy consumption. Besides, the potential negative effects of UHI can be prevented from China in many ways, such as urban greening, cool material, water bodies, urban ventilation, etc. These strategies could have a substantial impact on the overall urban thermal environment if they can be used in the project design stage of urban planning and implemented on a large scale. Therefore, this study is useful to deepen the understanding of the physical mechanisms of UHI and provide practical approaches to fight the UHI for the urban planners, public health officials, and city decision-makers in China.

scholarly journals Metrics for Measuring Sustainable Product Design Concepts

Energies ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3469
Author(s):  
Ji Han ◽  
Pingfei Jiang ◽  
Peter R. N. Childs
Keyword(s):  
Product Design ◽  
End Of Life ◽  
Environmental Impacts ◽  
Conceptual Design ◽  
Design Stage ◽  
Sustainable Product Design ◽  
Early Design ◽  
Design Concepts ◽  
Concept Evaluation ◽  
Sustainable Product

Although products can contribute to ecosystems positively, they can cause negative environmental impacts throughout their life cycles, from obtaining raw material, production, and use, to end of life. It is reported that most negative environmental impacts are decided at early design phases, which suggests that the determination of product sustainability should be considered as early as possible, such as during the conceptual design stage, when it is still possible to modify the design concept. However, most of the existing concept evaluation methods or tools are focused on assessing the feasibility or creativity of the concepts generated, lacking the measurements of sustainability of concepts. The paper explores key factors related to sustainable design with regard to environmental impacts, and describes a set of objective measures of sustainable product design concept evaluation, namely, material, production, use, and end of life. The rationales of the four metrics are discussed, with corresponding measurements. A case study is conducted to demonstrate the use and effectiveness of the metrics for evaluating product design concepts. The paper is the first study to explore the measurement of product design sustainability focusing on the conceptual design stage. It can be used as a guideline to measure the level of sustainability of product design concepts to support designers in developing sustainable products. Most significantly, it urges the considerations of sustainability design aspects at early design phases, and also provides a new research direction in concept evaluation regarding sustainability.

scholarly journals Energy and Eco-Impact Evaluation of Fused Deposition Modeling and Injection Molding of Polylactic Acid

2021 ◽  
Vol 13 (4) ◽  
pp. 1875
Author(s):  
Emmanuel Ugo Enemuoh ◽  
Venkata Gireesh Menta ◽  
Abdulaziz Abutunis ◽  
Sean O’Brien ◽  
Labiba Imtiaz Kaya ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Plastic Injection Molding ◽  
Measurement Models ◽  
Fused Deposition ◽  
Dog Bone ◽  
Deposition Modeling ◽  
Plastic Injection

There is limited knowledge about energy and carbon emission performance comparison between additive fused deposition modeling (FDM) and consolidation plastic injection molding (PIM) forming techniques, despite their recent high industrial applications such as tools and fixtures. In this study, developed empirical models focus on the production phase of the polylactic acid (PLA) thermoplastic polyester life cycle while using FDM and PIM processes to produce American Society for Testing and Materials (ASTM) D638 Type IV dog bone samples to compare their energy consumption and eco-impact. It was established that energy consumption by the FDM layer creation phase dominated the filament extrusion and PLA pellet production phases, with, overwhelmingly, 99% of the total energy consumption in the three production phases combined. During FDM PLA production, about 95.5% of energy consumption was seen during actual FDM part building. This means that the FDM process parameters such as infill percentage, layer thickness, and printing speed can be optimized to significantly improve the energy consumption of the FDM process. Furthermore, plastic injection molding consumed about 38.2% less energy and produced less carbon emissions per one kilogram of PLA formed parts compared to the FDM process. The developed functional unit measurement models can be employed in setting sustainable manufacturing goals for PLA production.

scholarly journals Optimization of injection molding process for car fender in consideration of energy efficiency and product quality

2014 ◽  
Vol 1 (4) ◽  
pp. 256-265 ◽  
Author(s):  
Hong Seok Park ◽  
Trung Thanh Nguyen
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Injection Molding ◽  
Product Quality ◽  
Process Parameters ◽  
Optimization Problems ◽  
Computational Cost ◽  
Injection Molding Process ◽  
Molding Process ◽  
Nsga Ii

Abstract Energy efficiency is an essential consideration in sustainable manufacturing. This study presents the car fender-based injection molding process optimization that aims to resolve the trade-off between energy consumption and product quality at the same time in which process parameters are optimized variables. The process is specially optimized by applying response surface methodology and using nondominated sorting genetic algorithm II (NSGA II) in order to resolve multi-object optimization problems. To reduce computational cost and time in the problem-solving procedure, the combination of CAE-integration tools is employed. Based on the Pareto diagram, an appropriate solution is derived out to obtain optimal parameters. The optimization results show that the proposed approach can help effectively engineers in identifying optimal process parameters and achieving competitive advantages of energy consumption and product quality. In addition, the engineering analysis that can be employed to conduct holistic optimization of the injection molding process in order to increase energy efficiency and product quality was also mentioned in this paper.

Study on the impacts of peaking factors on a water distribution system in Germany

2010 ◽  
Vol 10 (2) ◽  
pp. 165-172 ◽  
Author(s):  
K. Diao ◽  
M. Barjenbruch ◽  
U. Bracklow
Keyword(s):  
Energy Consumption ◽  
Distribution System ◽  
Water Distribution ◽  
Water Distribution System ◽  
Water Distribution Network ◽  
Design Stage ◽  
Water Age ◽  
Specific System ◽  
Average Water

This paper aims to explore the impacts of peaking factors on a water distribution system designed for a small city in Germany through model-based analysis. As a case study, the water distribution network was modelled by EPANET and then two specific studies were carried out. The first study tested corresponding system-wide influences on water age and energy consumption if the peaking factors used at design stage are inconsistent with ones in real situation. The second study inspected the possible relationship between the choice of peaking factors and budgets by comparing several different pipe configurations of the distribution system, obtained according to variety of peaking factors. Given the analysis results, the first study reveals that average water age will increase if peaking factors estimated at design stage are larger than real values in that specific system, and vice versa. In contrast, energy consumption will increase if peaking factors defined for system design are smaller than ones in real case, and vice versa. According to the second study, it might be possible to amplify peaking factors for design dramatically by a slight increase in the investment on this system. However, further study on budget estimation with more factors and detailed information considered should be carried out.

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