Energy-Efficient optimization of forging process considering the manufacturing history

Abstract

Increasing the energy efficiency of manufacturing processes is one of the many ways to reduce manufacturing cost and to resolve environmental issues. This paper systematically investigates the manufacturing process of an automotive crankshaft via a numerical simulation approach towards energy savings. The aim of this work is to propose potential solutions for improving the energy efficiency of the forging process chain in which energetically relevant parameters are optimized variables. The process chain is holistically optimized because the manufacturing history among the different processing steps is considered. We developed a discrete-event simulation based method to facilitate the holistic optimization of the forging process chain with regards to energy efficiency. To elucidate the weaknesses of the current process chain, manufacturing data were examined. Subsequently, a discrete-event simulation (DES) model was used in conjunction with design of experiments (DOE) in order to determine significant parameters as well as optimization scenarios. Finally, energy consumption optimizations were realized based on a consideration of the parameter adjustments. The research results show that the energy efficiency of the forging process chain could be improved by approximately 10% compared to the current state. Therefore, this work contributes to make the manufacturing crankshaft become greener and more efficient.