As energy efficiency increases in importance, researchers have identified manufacturing processes as opportunities where energy consumption can be reduced. Drawing is one widely employed, energy intensive manufacturing process, which could benefit by analysis of energy consumption during operation. To optimize the energy consumption of the drawing process, this paper developed an explicit model to quantify the process energy for the cylindrical drawing process by analyzing the dynamic punch force during the process. In this analysis, the evolution of the stress and strain was analyzed in the drawn part by considering all the structure parameters of the drawn part. The stress and strain analyses were integrated into an overall process energy model, and the behavior of the model was classified into three categories, based on their physical mechanisms, i.e., deformation energy, bending energy, and friction energy. The model was validated using numerical experiments designed by the Taguchi method where two different kinds of materials were tested over 18 runs. The results from the numerical experiments were compared with those from the model, and show that the maximum variation of the process energy predicted by this model is less than 10% for a given part. Sensitivity analysis was performed on the model to understand the contributions of the process parameters on the process energy to guide process optimization for lower energy consumption. The established model can assist in the rapid design of drawn parts with lower embodied energy.
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February 2019
Research-Article
Modeling and Analysis of the Process Energy for Cylindrical Drawing
Lei Li,
Lei Li
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: hfut_lilei@hotmail.com
Hefei University of Technology,
Hefei 230009, China
e-mail: hfut_lilei@hotmail.com
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Haihong Huang,
Haihong Huang
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: huanghaihong@hfut.edu.cn
Hefei University of Technology,
Hefei 230009, China
e-mail: huanghaihong@hfut.edu.cn
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Fu Zhao,
Fu Zhao
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088;
Purdue University,
West Lafayette, IN 47907-2088;
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: fzhao@purdue.edu
Purdue University,
West Lafayette, IN 47907-2088
e-mail: fzhao@purdue.edu
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Xiang Zou,
Xiang Zou
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: xiangzouhfut@163.com
Hefei University of Technology,
Hefei 230009, China
e-mail: xiangzouhfut@163.com
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Gamini P. Mendis,
Gamini P. Mendis
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: gmendis@purdue.edu
Purdue University,
West Lafayette, IN 47907-2088
e-mail: gmendis@purdue.edu
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Xiaona Luan,
Xiaona Luan
School of Mechanical Engineering,
Shandong University,
Jinan 250061, China;
Shandong University,
Jinan 250061, China;
Key Laboratory of High-efficiency and Clean
Mechanical Manufacture (Ministry of Education),
Shandong University,
Jinan 250061, China
e-mail: xiaona0412@126.com
Mechanical Manufacture (Ministry of Education),
Shandong University,
Jinan 250061, China
e-mail: xiaona0412@126.com
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Zhifeng Liu,
Zhifeng Liu
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: zhfliuhfut@126.com
Hefei University of Technology,
Hefei 230009, China
e-mail: zhfliuhfut@126.com
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John W. Sutherland
John W. Sutherland
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: jwsuther@purdue.edu
Purdue University,
West Lafayette, IN 47907-2088
e-mail: jwsuther@purdue.edu
Search for other works by this author on:
Lei Li
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: hfut_lilei@hotmail.com
Hefei University of Technology,
Hefei 230009, China
e-mail: hfut_lilei@hotmail.com
Haihong Huang
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: huanghaihong@hfut.edu.cn
Hefei University of Technology,
Hefei 230009, China
e-mail: huanghaihong@hfut.edu.cn
Fu Zhao
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088;
Purdue University,
West Lafayette, IN 47907-2088;
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: fzhao@purdue.edu
Purdue University,
West Lafayette, IN 47907-2088
e-mail: fzhao@purdue.edu
Xiang Zou
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: xiangzouhfut@163.com
Hefei University of Technology,
Hefei 230009, China
e-mail: xiangzouhfut@163.com
Gamini P. Mendis
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: gmendis@purdue.edu
Purdue University,
West Lafayette, IN 47907-2088
e-mail: gmendis@purdue.edu
Xiaona Luan
School of Mechanical Engineering,
Shandong University,
Jinan 250061, China;
Shandong University,
Jinan 250061, China;
Key Laboratory of High-efficiency and Clean
Mechanical Manufacture (Ministry of Education),
Shandong University,
Jinan 250061, China
e-mail: xiaona0412@126.com
Mechanical Manufacture (Ministry of Education),
Shandong University,
Jinan 250061, China
e-mail: xiaona0412@126.com
Zhifeng Liu
School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: zhfliuhfut@126.com
Hefei University of Technology,
Hefei 230009, China
e-mail: zhfliuhfut@126.com
John W. Sutherland
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: jwsuther@purdue.edu
Purdue University,
West Lafayette, IN 47907-2088
e-mail: jwsuther@purdue.edu
1Corresponding author.
Manuscript received February 27, 2018; final manuscript received November 4, 2018; published online December 24, 2018. Assoc. Editor: Karl R. Haapala.
J. Manuf. Sci. Eng. Feb 2019, 141(2): 021001 (13 pages)
Published Online: December 24, 2018
Article history
Received:
February 27, 2018
Revised:
November 4, 2018
Citation
Li, L., Huang, H., Zhao, F., Zou, X., Mendis, G. P., Luan, X., Liu, Z., and Sutherland, J. W. (December 24, 2018). "Modeling and Analysis of the Process Energy for Cylindrical Drawing." ASME. J. Manuf. Sci. Eng. February 2019; 141(2): 021001. https://doi.org/10.1115/1.4041924
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