An Environmental and Cost Analysis of Stamping Sheet Metal Parts
Little work has been done on quantifying the environmental impacts and costs of sheet metal stamping. In this work we present models that can be used to predict the energy requirements, global warming potential, human health impacts, and costs of making drawn parts using zinc (kirksite) die-sets and...
| Main Authors: | , , |
|---|---|
| Other Authors: | |
| Format: | Article |
| Language: | en_US |
| Published: |
American Society of Mechanical Engineers (ASME)
2017
|
| Online Access: | http://hdl.handle.net/1721.1/108775 https://orcid.org/0000-0001-6721-7026 https://orcid.org/0000-0002-4779-8211 https://orcid.org/0000-0001-7019-6887 |
| _version_ | 1811088584469381120 |
|---|---|
| author | Cooper, Daniel R. Rossie, Kathleen Eaton Gutowski, Timothy G |
| author2 | Massachusetts Institute of Technology. Department of Mechanical Engineering |
| author_facet | Massachusetts Institute of Technology. Department of Mechanical Engineering Cooper, Daniel R. Rossie, Kathleen Eaton Gutowski, Timothy G |
| author_sort | Cooper, Daniel R. |
| collection | MIT |
| description | Little work has been done on quantifying the environmental impacts and costs of sheet metal stamping. In this work we present models that can be used to predict the energy requirements, global warming potential, human health impacts, and costs of making drawn parts using zinc (kirksite) die-sets and hydraulic or mechanical presses. The methodology presented can also be used to produce models of stamping using other die materials, such as iron, for which casting data already exists.
An unprecedented study on the environmental impacts and costs of zinc die-set production was conducted at a leading Michigan die-maker. This analysis was used in conjunction with electrical energy measurements on forming presses to complete cradle-to-gate impact and cost analyses on producing small batch size hood and tailgate parts. These case studies were used to inform a generalized model that allows engineers to predict the impacts and costs of forming based on as little information as the final part material, surface area, thickness and batch size (number of units produced).
The case studies show that press electricity is an insignificant contributor to the overall impacts and costs. The generalized models highlight that while costs for small batch production are dominated by the die-set, the environmental impacts are often dominated by the sheet metal. These findings explain the motivation behind research into die-less forming processes such as incremental sheet forming, and emphasize the need to minimize sheet metal scrap generation in order to reduce environmental impacts. |
| first_indexed | 2024-09-23T14:04:21Z |
| format | Article |
| id | mit-1721.1/108775 |
| institution | Massachusetts Institute of Technology |
| language | en_US |
| last_indexed | 2024-09-23T14:04:21Z |
| publishDate | 2017 |
| publisher | American Society of Mechanical Engineers (ASME) |
| record_format | dspace |
| spelling | mit-1721.1/1087752022-10-01T18:59:43Z An Environmental and Cost Analysis of Stamping Sheet Metal Parts Cooper, Daniel R. Rossie, Kathleen Eaton Gutowski, Timothy G Massachusetts Institute of Technology. Department of Mechanical Engineering Cooper, Daniel R. Rossie, Kathleen Eaton Gutowski, Timothy G Little work has been done on quantifying the environmental impacts and costs of sheet metal stamping. In this work we present models that can be used to predict the energy requirements, global warming potential, human health impacts, and costs of making drawn parts using zinc (kirksite) die-sets and hydraulic or mechanical presses. The methodology presented can also be used to produce models of stamping using other die materials, such as iron, for which casting data already exists. An unprecedented study on the environmental impacts and costs of zinc die-set production was conducted at a leading Michigan die-maker. This analysis was used in conjunction with electrical energy measurements on forming presses to complete cradle-to-gate impact and cost analyses on producing small batch size hood and tailgate parts. These case studies were used to inform a generalized model that allows engineers to predict the impacts and costs of forming based on as little information as the final part material, surface area, thickness and batch size (number of units produced). The case studies show that press electricity is an insignificant contributor to the overall impacts and costs. The generalized models highlight that while costs for small batch production are dominated by the die-set, the environmental impacts are often dominated by the sheet metal. These findings explain the motivation behind research into die-less forming processes such as incremental sheet forming, and emphasize the need to minimize sheet metal scrap generation in order to reduce environmental impacts. United States. Department of Energy (Grant: DOE/EE-0998) 2017-05-09T14:50:12Z 2017-05-09T14:50:12Z 2016-07 Article http://purl.org/eprint/type/ConferencePaper 978-0-7918-4991-0 http://hdl.handle.net/1721.1/108775 Cooper, Daniel R., Kathleen E. Rossie, and Timothy G. Gutowski. “An Environmental and Cost Analysis of Stamping Sheet Metal Parts.” ASME 2016 11th International Manufacturing Science and Engineering Conference, 27 June-1 July, Blacksburg, Virginia, USA, ASME, 2016. © 2016 by ASME https://orcid.org/0000-0001-6721-7026 https://orcid.org/0000-0002-4779-8211 https://orcid.org/0000-0001-7019-6887 en_US http://dx.doi.org/10.1115/MSEC2016-8880 Proceedings of the ASME 2016 International Manufacturing Science and Engineering Conference MSEC2016 Article is made available in accordance with the publisher's policy and may be subject to US copyright law. Please refer to the publisher's site for terms of use. application/pdf American Society of Mechanical Engineers (ASME) American Society of Mechanical Engineers (ASME) |
| spellingShingle | Cooper, Daniel R. Rossie, Kathleen Eaton Gutowski, Timothy G An Environmental and Cost Analysis of Stamping Sheet Metal Parts |
| title | An Environmental and Cost Analysis of Stamping Sheet Metal Parts |
| title_full | An Environmental and Cost Analysis of Stamping Sheet Metal Parts |
| title_fullStr | An Environmental and Cost Analysis of Stamping Sheet Metal Parts |
| title_full_unstemmed | An Environmental and Cost Analysis of Stamping Sheet Metal Parts |
| title_short | An Environmental and Cost Analysis of Stamping Sheet Metal Parts |
| title_sort | environmental and cost analysis of stamping sheet metal parts |
| url | http://hdl.handle.net/1721.1/108775 https://orcid.org/0000-0001-6721-7026 https://orcid.org/0000-0002-4779-8211 https://orcid.org/0000-0001-7019-6887 |
| work_keys_str_mv | AT cooperdanielr anenvironmentalandcostanalysisofstampingsheetmetalparts AT rossiekathleeneaton anenvironmentalandcostanalysisofstampingsheetmetalparts AT gutowskitimothyg anenvironmentalandcostanalysisofstampingsheetmetalparts AT cooperdanielr environmentalandcostanalysisofstampingsheetmetalparts AT rossiekathleeneaton environmentalandcostanalysisofstampingsheetmetalparts AT gutowskitimothyg environmentalandcostanalysisofstampingsheetmetalparts |