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Exergy analysis of incremental sheet forming

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Abstract

Research in the last 15 years has led to die-less incremental forming processes that are close to realization in an industrial setup. Whereas many studies have been carried out with the intention of investigating technical abilities and economic consequences, the ecological impact of incremental sheet forming (ISF) has not been studied so far. Using the concept of exergy analysis, two ISF technologies, namely single sided and double sided incremental forming, are investigated and compared to conventional forming and hydroforming. A second exergy analysis is carried out with the purpose of examining the environmental impact of different forming technologies from a supply chain perspective. Therefore, related upstream activities (die set production, aluminum sheet production and energy conversion and supply) are included into the exergy analysis. The entire supply chain is modeled with Matlab/Simulink. The results of both analyses suggest that ISF is environmentally advantageous for prototyping and small production runs.

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Acknowledgments

The authors gratefully acknowledge the support of the U.S. Department of Energy, Award DE-EE0003460, technical contact Dr. Debo Archbhaumik.

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Authors and Affiliations

  1. Laboratory for Manufacturing and Productivity, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, MA, 02139, USA

    M. A. Dittrich & T. G. Gutowski

  2. Department of Mechanical Engineering, Northwestern University, 2145 Sheridan Rd., Evanston, IL, 6020, USA

    J. Cao

  3. Mechanical Engineering Faculty, Penn State Erie, The Behrend College, 5091 Station Road, Erie, PA, 16563, USA

    J. T. Roth

  4. Ford Motor Company, Dearborn, MI, 48124, USA

    Z. C. Xia, V. Kiridena & F. Ren

  5. Institute of Production Engineering and Machine Tools (IFW), Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    H. Henning

  6. Department of Civil and Environmental Engineering, Northwestern University, 2145 Sheridan Rd., Evanston, IL, 6020, USA

    J. Cao

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  1. M. A. Dittrich
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  2. T. G. Gutowski
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  3. J. Cao
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  4. J. T. Roth
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  5. Z. C. Xia
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  6. V. Kiridena
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  7. F. Ren
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  8. H. Henning
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Correspondence to M. A. Dittrich.

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Dittrich, M.A., Gutowski, T.G., Cao, J. et al. Exergy analysis of incremental sheet forming. Prod. Eng. Res. Devel. 6, 169–177 (2012). https://doi.org/10.1007/s11740-012-0375-9

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  • DOI: https://doi.org/10.1007/s11740-012-0375-9

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