Higher Life Cycle Costs Research Articles

Cost-oriented fire safety design of urban structures

Providing adequate fire safety for urban buildings is a life-saving goal, and can be addressed in different ways. Reported studies integrating fire safety and life cycle cost (LCC) of conventional urban structures are rare. To address this gap, a cost–performance framework was developed. Four- and seven-storey steel (with and without fireproofing coatings) and reinforced concrete (RC) structures were designed, first for conventional loads and then fireproofed to meet their required fire-resistance rating. A range of sprinkler spacings, from 3200 mm (based on NFPA 13) to 12 000 mm, was configured. Fire was simulated using a fire dynamic simulation tool and the results were used to monitor evacuation plans and structural responses. The steel structures were additionally analysed under the assumption that they were not fireproofed. Human and financial damage costs were then estimated and the LCC for every case/scenario was determined. Interestingly, the results showed that the optimum LCC was not achieved for cases designed based on NFPA 13; instead, a sprinkler spacing of 6000 mm led to the optimum LCC. It was also found that steel structures without fireproofing do not have a higher LCC if the sprinklers are placed over a shorter distance. This result could be particularly beneficial for existing structures that are not fireproofed.

The impact of green roofs’ composition on its overall life cycle

Green roof systems have been developed to improve the environmental, economic, and social aspects of sustainability. Selecting the appropriate version of the green roof composition plays an important role in the life cycle assessment of a green roof. In this study, 10 compositions of an intensive green roof for moderate zone and 4 green roof compositions for different climatic conditions were designed and comprehensively assessed in terms of their environmental and economic impacts within the “Cradle-to-Cradle” system boundary. The assessment was carried out over a 50-year period for a moderate climate zone. The results showed that asphalt strips and concrete slab produced the highest total emissions. It was found that most greenhouse gases emissions were released in the operational energy consumption phase and in the production phase. The energy consumption phase (48.78%) for automatic irrigation and maintenance caused the highest Global Warming Potential (GWP) value (758.39 kg CO2e) in the worst variant, which also caused the highest life cycle cost (878.47€). On the contrary, in the best variant, planting more vegetation and lower maintenance and irrigation requirements led to a reduction in GWP (445.0 kg CO2e), but in terms of cost (506.6€) this composition didn't represent the best variant. The Global Warming Potential Biogenic (GWP-bio) compared to the Global Warming Potential Total (GWP-total) represents a proportion ranging from 0.8% to 78% depending on the proposed vegetation. Overall higher biogenic carbon values (up to 1525 kg CO2e) were observed for the proposed tall vegetation of Magnolia, Red Mulberry, Hawthorne, Cherry, and Crab-apple Tree. Based on the results of the multicriteria analysis, which included core environmental & economic parameters, biogenic carbon emission levels, the outcome of this paper proposed optimal green roof composition. Optimal intensive green roof composition was subjected to a sensitivity analysis to determine the impact of changing climatic conditions on CO2 emissions and life cycle costs. The results of the sensitivity analysis show that the optimal variant of the green roof can be implemented in the cold and subtropical zone with regard to CO2 emissions, but not with regard to life cycle costs.

Increasing school building usage through adaptable building design: A quantitative sustainability assessment

While school buildings have the potential to form the hearth of a local community, they currently remain unused for longer periods of time out of school hours in several regions. To exploit this large sustainability potential, school buildings must be able to allow for a flexible building usage. First, this study explores whether letting school infrastructure to external users can be economically profitable. Second, it tackles the knowledge gap on how ventilation systems can facilitate a short- and medium-long-term flexible building usage in a sustainable manner, which is essential to achieve a more extensive school building usage. To answer these research questions, a case study is carried out which includes a flexible building usage that based on the needs of educational stakeholders. The results of the profitability analyses indicate that it is possible for schools to yield substantial profits over a period of 20 years and that the financial risks are low. Next, a life cycle assessment (LCA) and life cycle cost assessment (LCCA) are carried out on three different ventilation strategies. It is found that a decentralized balanced mechanical ventilation system has the lowest environmental impact and life cycle cost, since this system requires few adaptions during the study period. The mechanical exhaust ventilation system has the highest environmental impact, while the centralized balanced mechanical ventilation system has the highest life cycle cost. An important insight of this sustainability assessment is that the material-related impact increases in a flexible context and that it sometimes outweighs the energy-related impact.

Prediction and Optimization Analysis of the Performance of an Office Building in an Extremely Hot and Cold Region

The White Paper on Peak Carbon and Carbon Neutral Action 2022 states that China is to achieve peak carbon by 2030 and carbon neutrality by 2060. Based on the “3060 dual-carbon” goal, how to improve the efficiency of energy performance is an important prerequisite for building a low-carbon, energy-saving, green, and beautiful China. The office performance building studied in this paper is located in the urban area of Turpan, where the climate is characterized by an extremely hot summer environment and a cold winter environment. At the same time, the building is oriented east–west, with the main façade facing west, and the main façade consists of a large area of single-layer glass curtain wall, which is affected by western sunlight. As a result, there are serious problems with the building’s energy consumption, which in turn leads to excessive carbon emissions and high life cycle costs for the building. To address the above problems, this paper analyzes and optimizes the following four dimensions. First, the article creates a Convolutional Neural Network (CNN) prediction model with Total Energy Use in Buildings (TEUI), Global Warming Potential (GWP), and Life Cycle Costs (LCC) as the performance objectives. After optimization, the R2 of the three are 0.9908, 0.9869, and 0.9969, respectively, thus solving the problem of low accuracy of traditional prediction models. Next, the NSGA-II algorithm is used to optimize the three performance objectives, which are reduced by 41.94%, 40.61%, and 31.29%, respectively. Then, in the program decision stage, this paper uses two empowered Topsis methods to optimize this building performance problem. Finally, the article analyzes the variables using two sensitivity analysis methods. Through the above research, this paper provides a framework of optimization ideas for office buildings in extremely hot and cold regions while focusing on the four major aspects of machine learning, multi-objective optimization, decision analysis, and sensitivity analysis systematically and completely. For the development of office buildings in the region, whether in the early program design or in the later stages, energy-saving measures to optimize the design have laid the foundation of important guidelines.

Finite element simulation analysis of flow heat transfer behavior and molten pool characteristics during 0Cr16Ni5Mo1 laser cladding

0Cr16Ni5Mo1 super martensitic stainless steel has excellent weldability and is an economical material with a high life cycle and low cost, but there are few researches and applications of this material in additive manufacturing. In order to realize the application of 0Cr16Ni5Mo1 large-area laser cladding technology, the multi-track lap cladding of the material was studied. In this work, a multi-physical finite element model of multi-layer multi-track laser cladding was established, taking into account thermodynamic processes such as phase transition, Marangoni convection, and buoyancy. The flow and heat transfer behavior of 0Cr16Ni5Mo1 in multi-layer multi-track laser cladding process and the characteristics of the molten pool are studied. The research focused on the flow heat transfer behavior and molten pool characteristics of 0Cr16Ni5Mo1 during multi-layer multi-track laser cladding. The discussed aspects include the evolution history of the temperature field within the molten pool, flow field characteristics, molten pool dimensions, and dilution ratio under various laser powers and overlap rates. The results show that with the increase of overlap rate, the morphology of molten pools in different clad tracks will also change, and the flow rate, dilution ratio, and length of molten pools in the second track are negatively correlated, while the temperature and height of molten pools are positively correlated. As the laser power increases, all the characteristic quantities are positively correlated with it.

Selecting Appropriate Energy Source Options for an Arctic Research Ship

Interest in more sustainable energy sources has increased rapidly in the maritime industry, and ambitious goals have been set for decreasing ship emissions. All industry stakeholders have reacted to this with different approaches including the optimisation of ship power plants, the development of new energy-improving sub-systems for existing solutions, or the design of entirely novel power plant concepts employing alternative fuels. This paper assesses the feasibility of different ship energy sources for an icebreaking Arctic research ship. To that end, possible energy sources are assessed based on fuel, infrastructure availability and operational endurance criteria in the operational area of interest. Promising alternatives are analysed further using the evidence-based Strengths, Weaknesses, Opportunities, and Threats (SWOT) method. Then, a more thorough investigation with respect to the required fuel tank space, life cycle cost, and CO2 emissions is implemented. The results demonstrate that marine diesel oil (MDO) is currently still the most convenient solution due to the space, operational range, and endurance limitations, although it is possible to use liquefied natural gas (LNG) and methanol if the ship’s arrangement is radically redesigned, which will also lead to reduced emissions and life cycle costs. The use of liquefied hydrogen as the only energy solution for the considered vessel was excluded from the potential options due to low volumetric energy density, and high life cycle and capital costs. Even if it is used with MDO for the investigated ship, the reduction in CO2 emissions will not be as significant as for LNG and methanol, at a much higher capital and lifecycle cost. The advantage of the proposed approach is that unrealistic alternatives are eliminated in a systematic manner before proceeding to detailed techno-economic analysis, facilitating the decision-making and investigation of various options in a more holistic manner.

Codified robust optimal design base shear of structures: Methodology and application to reinforced concrete buildings

This paper proposes a methodology for codifying the robust optimal design base shear of buildings that minimizes the lifecycle cost (LCC) and its uncertainty. This methodology, while preserving the current format of the base shear equation in seismic codes, calibrates its factors, i.e., the response modification factor, the site class factor, and the importance factor, by minimizing the expected LCC and its variance through a bilevel optimization. Hence, it results in a design that not only is optimal based on the expected cost theory, but also is robust, making large realizations of seismic losses significantly less likely. To showcase the application of the methodology, the optimal design base shear coefficient, optimal response modification factor, optimal site class factor, and optimal importance factor are determined for four- and eight-story buildings of different importance levels on various site classes at 5706 sites across 14 countries in Western Asia. The resulting design base shears are then compared to those obtained from ASCE 7–16 provisions, which are widely adopted by the codes of the considered region. The design base shears resulting from the proposed approach for ordinary buildings are on average twice those obtained through ASCE 7–16 provisions across various combinations of building heights and site classes for the considered region. As such, the proposed approach yields an average reduction of 18% and up to 56% in expected seismic losses while also reducing the expected LCC by 1.9% and 11.6% and its variance by 38% and 55% for different importance levels. The substantial reductions achieved by the proposed approach suggest that the likelihood of incurring high lifecycle costs and catastrophic losses is significantly reduced.

Integrating Facilities Management knowledge in municipal school building: Swedish case studies

Due to population growth and evolving demands for flexible premises, the design and construction of school facilities is currently a highly prioritized activity for many Swedish municipalities. However, previous research has found that facilities management (FM) knowledge is rarely integrated in the design of schools, resulting in construction deficiencies, high lifecycle costs and lower user functionality. The propensity to integrate FM knowledge in school projects varies greatly across Swedish municipalities, but the underlying factors shaping such organizational capabilities are less studied. In response, this study investigates how Swedish municipalities are currently organizing the integration of FM knowledge in the design phase of schools. The case study includes three municipalities of different sizes, where 18 interviews were performed with 22 representatives from users, operations and maintenance, construction project management, procurement and top management. To analyse the findings, a framework based on knowledge management was applied. The findings showed that FM knowledge is increasingly translated into codified processes and project planning standards and guidelines, but that personalized knowledge still plays an important role. Further, knowledge sharing in this field is complex and municipalities still face challenges despite improvement efforts. Thus, there is considerable potential to strengthen knowledge codification and sharing between municipalities and on the sector level. The study also points at the importance of studying knowledge governance at higher municipal levels, where many key organizational decisions are made.

Comparative Analysis Optimal Designs for Passive, Electrified, and Net Zero Energy Residential Buildings

Abstract In this paper, a life cycle cost-based optimization analysis is carried out to compare the energy and cost performance of diverse sustainable designs of a residential building. These designs include code optimal, net zero energy building, and passive house. It is found that in the case where natural gas is employed, a total energy savings of 77% is optimal. The cost optimal design for electrification achieves 100.12% of energy savings relative to the baseline design but results slightly high life cycle cost than that of the gas cost optimal design. In addition, the results indicate that due to the additional capital costs for the required energy efficient measures, the passive house case is less economically optimal than NZEB design options. Overall, the most cost-optimal designs are found to be for natural gas heated homes with marginally better energy performance than the applicable currently energy efficiency code with 10 kW solar panels.

Applications of Industry 4.0 Technologies in Warehouse Management: A Systematic Literature Review

Background: Recent literature indicates that warehouse management costs account for a significant portion of overall logistics costs in companies. Warehousing requires the classification, controlling and management of inventory as well as processing of related information. Therefore, adopting efficient and reasonable warehouse management measures to achieve effective management and control of materials is a key means to flexibly adjusting the supply and demand of storage materials and reduce operating costs. There remains a gap in the understanding of benefits and barriers to the full adoption of Industry 4.0 technologies and decision support systems (DSSs) in warehouse management. Methods: This work applies a systematic literature review methodology of recent implementation case studies to analyze documented barriers and benefits of Industry 4.0 technology adoption in warehouse management. For analysis, benefits and barriers are ranked in order of importance using Pareto analysis based on their frequency of occurrence. Results: Improved process efficiency, the availability of real-time data, added competitive advantage and the ability to integrate business activities digitally are the top four most important benefits of implementing Industry 4.0 technologies and decision support systems in warehouse management. The prominent barriers to implementation are high life cycle cost, challenging physical environment/layout, inadequate supporting resource constraints, increased security risk and high energy consumption. Conclusions: Barriers to implementing Industry 4.0 technologies are interrelated in nature and prevent businesses from realizing the full benefit of implemented Industry 4.0 technologies. Adequate financial support, new knowledge and skills are required to be able to ensure the successful implementation of Industry 4.0 in warehousing management.

Boosting productivity with tech

Boosting productivity with tech

Performance of Sustainable Road Pavements Founded on Clay Subgrades Treated with Eco-Friendly Cementitious Materials

Clays encountered during road construction are mostly weak and result in major pavement failures due to their low California bearing ratio (CBR) and high swelling potential. In this study, sustainable and eco-friendly waste materials including brick dust waste (BDW), ground granulated blastfurnance slag (GGBS), recycled plastic (RP) and recycled glass (RG) at varying proportions of 11.75% and 23.5% were used as partial replacement for cement and lime in clay treatment. After determining the water content by conducting Atterberg limit and compaction test, A CBR and swell characteristics of treated and untreated clay were also conducted. A road pavement design was conducted using the Design Manual for Road and Bridges (DMRB) as a guide to determine the performance of treated clay with varying CBR values. A road pavement failure analysis was also conducted to understand the defect formation within pavement structures supported by eco-friendly treated clay. The embodied carbon of treated clay was calculated and a life cycle cost analysis (LCCA) of flexible pavement with treated clay and road with imported materials was conducted. The results show a liquid limit of 131.26 and plastic limit of 28.74 for high plasticity index (clay 1) and liquid limit of 274.07 and a plastic limit of 45.38 for extremely high plasticity index (clay 2). An increase in CBR values from 8% and 9% to 57% and 97% with a reduction in swell values from 4.11% and 5.03% to 0.38% and 0.56% were recorded. This resulted in a reduction in pavement thickness and stresses within the road pavement leading to reduced susceptibility of the pavement to fatigue, rutting and permanent deformation. Very low embodied carbon was recorded for eco-friendly treated clay and a high life cycle cost (LCC) with clay removed and replaced with imported materials compared with clay treated using eco-friendly waste materials. The study concluded that carbon and overall construction costs can be reduced using waste materials in road construction. Owners and operators can save money when clay is treated and used in road construction instead of removing clay and replacing it with imported materials.

Technical, economic, and environmental feasibility of alternative fuel heavy-duty vehicles in Iceland

The literature available on alternative fuel heavy-duty trucks often focuses on greenhouse gas emissions and total cost of ownership assessments, drawing an insightful but incomplete picture of the best solutions for each context. Using Iceland as case study, this paper attempts to provide a broader perspective by including energy security, technical feasibility and air pollutant emissions in the assessment. AFLEET and GREET are used to calculate the life cycle emissions and the total cost of ownership of 10 heavy-duty powertrains using representative vehicle categories in Iceland: regional and delivery trucks. The technical feasibility of battery-electric and hydrogen trucks is addressed in terms of battery/tank required capacity for representative fuel efficiency values, while the resources available in Iceland are used to determine the local fuel production capacity and the potential impact of each alternative fuel pathway on energy security. The results suggest that battery-electric trucks present the highest environmental and economic benefits, although the limited range of current battery technology implies a high penetration only in delivery trucks. Hydrogen and compressed natural gas pathways present attractive results for regional trucks, although their implementation is limited due to high life cycle costs and insufficient feedstock capacity. Renewable diesel stands out as a potential solution to fill the gap for regional trucks as it presents overall satisfactory results throughout all dimensions addressed. The results suggest that a 100% alternative fuel heavy-duty fleet energy demand could be met using local resources in Iceland.

Life cycle cost analysis of wastewater treatment technologies

With the ever-increasing population, volumes of wastewater treatment are a major concern in our country. The Activated Sludge Process (ASP), Biological Filtration and Oxygenated Reactor (BIOFOR), Upflow Anaerobic Sludge Blanket (UASB), and Moving Bed Bio Reactor (MBBR) are all monetarily investigated in the present study using the Life Cycle Cost Assessment (LCCA) tool. In this study, life cycle costing is done using the present value method, which involves discounting the costs for a 20-year economic life. The costs of treating wastewater per million litres per day (MLD) of wastewater treatment technology are obtained from the literature. Moreover, this study takes into account the capital, annual operation, energy, salvage, and replacement costs to compare the life cycle costs of ASP, UASB, BIOFOR, and MBBR to make the best guess of an economical technology. The LCCA demonstrates that the MBBR has the highest costs of treatment, resulting in the highest Life Cycle Cost (LCC). BIOFOR has the largest energy requirement making LCC the second-highest among the technologies. In India, ASP is one of the most widely used technologies, whose LCC is the third most advanced of the four technologies. Because of its lower energy and operating costs, UASB has the lowest LCC.

Improvement in Durability and Mechanical Performance of Concrete Exposed to Aggressive Environments by Using Polymer.

Concrete is the most widely used construction material. However, it cannot sustain the harsh environment and can easily deteriorate. It results in repair and reworks that amount to a considerable loss of money and time. The life span of concrete reduces if exposed to external attacks, for instance, sulfate attacks, alkali-silica reactions, corrosion, and drying shrinkage. These ubiquitous attacks cause a reduction in service life and raise the need for early repair and maintenance, resulting in higher life cycle costs and structural failures. To resolve these issues, the potential of styrene-butadiene-rubber (SBR) ultrafine powder as cement replacement polymeric admixture at 0%, 3%, 5%, 7%, and 10% have been evaluated. The effect of SBR-powder on concrete is investigated by conducting an alkali-silica reactivity test (ASR), rapid-chloride-permeability test (RCPT), drying shrinkage, and sulfate resistivity tests. Workability, compressive and flexural strength tests are also conducted. For ASR and drying shrinkage, mortar bar samples were cast, exposed to respective environments, and the percentage change in length was measured. For mechanical tests and RCPT, prisms, cylinders and cubes were cast and tested at 28 days. The SBR-powder modification reduces concrete’s permeability, drying shrinkage, and expansions due to ASR and sulfate attacks. SBR powder increased workability by 90%, compressive strength by 23%, and flexural strength by 9.4% in concrete when used at 10% cement replacement by weight. The SBR-powder (10%) modification reduced the RCPT value by up to one-third (67%), drying shrinkage by 53%, ASR by 57%, and sulfate reaction by 73%. Consequently, SBR powder usage can adequately improve the workability, mechanical properties, and durability of the concrete and lead to advanced sustainable concrete with low repair requirements.

Towards circular manufacturing systems implementation: A complex adaptive systems perspective using modelling and simulation as a quantitative analysis tool

A transition towards circular manufacturing systems (CMS) has brought awareness of untapped economic and environmental benefits for the manufacturing industry. Conventional manufacturing systems already present a high level of complexity in terms of physical flows of materials and products as well as information and financial flows linked to them. Closing the loop of materials and products through multiple lifecycles, as proposed in CMS, increases this complexity manifold. To support practitioners in implementing CMS through enhanced decision-making, this research studies CMS from a complex adaptive systems (CAS) perspective and proposes to exploit methods and tools used in the study of CAS to characterise, model and analyse CMS. By viewing CMS as CAS composed of autonomous, interacting agents, this research proposes a multi-method model architecture for modelling and simulating CMS. The different CMS stakeholders are modelled individually as autonomous agents by integrating agent-based, discrete-event, and/or system dynamics modules within each agent to capture their diverse and heterogeneous nature. The applicability of the proposed multi-method approach is illustrated through a case study of a white goods manufacturing company implementing CMS in practice. This case study shows the relevance and feasibility of the proposed multi-method approach as a decision support tool for the systemic exploration and quantification of CMS. It also shows how a transition towards CMS necessitates a lifecycle approach in terms of costs, revenues and environmental impacts to identify hotspots and, therefore, design circular systems that are viable in both economic and environmental terms. In fact, the analyses of the simulation results indicate how decisions in terms of business models, product design, and supply chain might affect the CMS performance of the case company. For instance, implementing a service-based model led to a high number of usecycles (on average six usecycles per washing machine), which, in turn, led to high lifecycle costs and emissions due to more frequent transportation and recovery operations. Similarly, the deployment of long-lasting washing machines, which is a core principle of CMS, led to high manufacturing costs. Due to the high initial costs and a time mismatch between revenues and costs in the service-based model, it required a longer time for the company to reach the break-even point (approximately 23 months). Overall, the case study shows that multi-method simulation modelling can provide decision-making support for a successful implementation of CMS.

Multi-objective optimisation for building integrated photovoltaics (BIPV) roof projects in early design phase

Building-integrated photovoltaics (BIPV) is an excellent renewable energy application for building envelopes. In Australia, BIPV roofing is considered to be promising because of recent major concerns about fire risks of façades. However, the integration of PV into building envelope elements is a complicated process which, if not done properly, may lead to failure of the BIPV system. Therefore, feasible BIPV design solutions need to be examined in terms of life-cycle cost and energy performance from the early design phase of a BIPV envelope project. There have been few investigations of the identification of feasible BIPV design options in the early design phase to enable product selection and parametric tests. This study explores a multi-objective optimization method which formulates feasible BIPV envelope design options which have relatively high energy generation and low life cycle costs to informed decision making. The optimisation process has four segments: data inputs, simulator, optimizer and pareto front based optimised BIPV solutions. The proposed multi- objective optimization process is applied in a BIPV roof application using a case study in Australia with roof sheets and skylights. The results demonstrate seven optimum roof sheet BIPV design solutions and fourteen optimum skylight BIPV design solutions to enable design makers to compare and select the most appropriate. The life cycle cost, life cycle energy, CO2 emissions avoided, net present value, payback period, and levelized cost of energy of BIPV solutions vary based on the BIPV modules, tilt angles and placement locations. The proposed optimization method is a helpful guide for BIPV design professionals to identify suitable BIPV design options in the early design phase instead of relying on rule-of-thumb experience.

A global overview of renewable energy strategies

<abstract> <p>Population expansion and increased industrialization are driving up global energy demand. Similarly, the most populous African country, Nigeria generates and transmits electricity far less than is required to meet her basic residential and industrial demands. Alternative means such as fossil fuel-powered generators to complement these demands are still not sufficient to meet these demands with notice to their limitation such as high lifecycle cost and carbon dioxide emission. Renewable energy resources are suitable substitutes for existing electricity sources to fulfil growing demand. Extensively in this paper, a review on the research progress of Hybrid Renewable Energy Systems (HRESs) and Integrated Renewable Energy Systems (IRESs) in the different continents of the world was presented considering methodologies, approaches, and parameters such as technical, economic, and emission limitation in determining the optimal renewable energy system in their present locality. According to the study's findings, about 63% and 22% of the research were conducted in Asia and Africa respectively, from which the research is mostly conducted in rural and remote areas of these continents.</p> </abstract>

Lifecycle cost and carbon implications of residential solar-plus-storage in California

SummaryCapacities of residential photovoltaics (PV) and battery storage are rapidly growing, while their lifecycle cost and carbon implications are not well understood. Here, we integrate PV generation and load data for households in California to assess the current and future lifecycle cost and carbon emissions of solar-plus-storage systems. Our results show that installing PV reduces $180–$730 and 110–570 kgCO2 per year per household in 2020. However, compared to solar-only system, adding battery storage increases lifecycle costs by 39%–67%, while impact on emissions is mixed (−20% to 24%) depending on tariff structure and marginal emission factors. In 2040, under current decarbonization and cost trajectories, solar-plus-storage leads to up to 31% higher lifecycle costs and up to 32% higher emissions than solar-only systems. Designing a tariff structure with wider rate spreads aligned with marginal carbon emissions, and reducing the costs and embodied emissions of batteries are crucial for broader adoption of low-carbon residential solar-plus-storage.

Bending fatigue life oriented tooth flank dry-grinding tool modification for cleaner manufacturing of spiral bevel gear product

Gear tooth flank dry-cutting was beget with emergent and disruptive NC technology. This new technology is enabling ever-higher levels of production efficiency and sustainability. It also has the potential to dramatically influence sustainable development of spiral bevel gear product. Sufficient guidance, in this respect, is lacking in the scholarly or practitioner literature. In this work, focusing on spiral bevel gear production, we further examine dry-cutting technology in terms of application and sustainability implications. We introduce bending fatigue life design into gear dry-grinding by considering various economic, environmental and social attributes. We also develop bending fatigue life oriented tooth flank dry-grinding tool modification by incorporating a high life cycle assessment (LCA) and low life cycle cost (LCC). At first, data-driven tool modification design relating to dry-grinding tool parameters is developed. Then, finite element method (FEM) based root bending fatigue assessment is performed by using the multiaxial fatigue damage model. Here, with data-driven finite element modeling, simulated loaded tooth contact analysis (SLTCA) is employed to root bending stress determination. They were introduced into the multiaxial fatigue damage model based fatigue life assessment. Moreover, focusing on the minimum fatigue at dangerous point namely fatigue limit, bending fatigue life oriented dry-grinding tool modification model considering geometric accuracy is established. Then, data-driven adaptive feedback and optimization is performed by using tool modification. The final output tool modification parameters can be used to obtain the cleaner manufacturing of gear product both flank geometric accuracy and fatigue life. Finally, the numerical instance was given to verify the proposed method. By building a bridge between the tool parameters in early design and the fatigue life in actual transmission, the proposed method can get a significantly important access to cleaner manufacturing of spiral bevel gears product.