An Environmental and Cost Analysis of Stamping Sheet Metal Parts
Name
Gutowski_An environmental and cost.pdf
Size
2.09 MB
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Adobe PDF
Checksum (MD5)
99436a66b52c02b65a4881551cf264b6
Author(s)
Cooper, Daniel A
Rossie, Kathleen Eaton
Gutowski, Timothy G
Date Issued
November 2016
Journal
Journal of Manufacturing Science and Engineering
Publisher
ASME International
Citation
Cooper, Daniel R., Kathleen E. Rossie, and Timothy G. Gutowski. “An Environmental and Cost Analysis of Stamping Sheet Metal Parts.” Journal of Manufacturing Science and Engineering 139.4 (2016): 041012. © 2017 by ASME
Version
Final published version
Abstract
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 the 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 the research into die-less forming processes such as incremental sheet forming, and emphasize the need to minimize the sheet metal scrap generation in order to reduce environmental impacts.
MIT Department
Lincoln Laboratory
Massachusetts Institute of Technology. Department of Mechanical Engineering
Terms of Use
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.
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DOI of Published Version
https://doi.org/10.1115/1.4034670
