Chapter
2.3 Energy Consumption in Unit Manufacturing Process
2.3.1 Basic Concepts of Energy, Power, and Work
2.3.2 Framework of Energy Consumption
2.4 Operation Plan Relevance to Energy Consumption
2.5 Energy Accounting in Unit Manufacturing Processes
2.6 Processing Energy in Unit Manufacturing Process
2.6.1 Cases of Processing Energy Modeling
2.6.1.2 Orthogonal Cutting
2.6.1.4 Specific Energy vs. MRR
2.7 Energy Reduction Opportunities
2.7.1 Shortening Process Chain by Hard Machining
2.7.2 Substitution of Process Steps
2.7.4 Adaptation of Cooling and Flushing Strategies
3.1.1 Steelmaking Technology
3.2.2 History of Aluminum Processing
3.2.3 Aluminum in Commerce
3.2.4 Aluminum Processing
3.2.6 Preparation of Carbon
3.2.7 Hall-Heroult Electrolytic Process
3.3.2 History of Titanium Processing
3.3.3 Titanium in Commerce
3.3.4 Titanium Processing Methods
3.3.7 Hunter Process and Kroll Process
3.3.8 Remelting Processes
3.3.9 Emerging Titanium Processing Technologies
3.4.1 Life Cycle Environmental and Cost Assessment
3.4.2 An Application of Polymer-Powder Processes
4 Energy Reduction in Manufacturing via Incremental Forming and Surface Microtexturing
4.1.1 Conventional Forming Processes
4.1.2 Energy Reduction via Incremental Forming
4.1.3 Challenges in Incremental Forming
4.1.3.1 Toolpath Planning for Enhanced Geometric Accuracy and Process Flexibility
4.1.3.2 Formability Prediction and Deformation Mechanics
4.1.3.3 Process Innovation and Materials Capability in DSIF
4.1.3.4 Future Challenges in Incremental Forming
4.2 Surface Microtexturing
4.2.1 Energy Based Applications of Surface Microtexturing
4.2.1.1 Microtexturing for Friction Reduction
4.2.1.2 Microtexturing Methods
4.2.1.3 Future Work in Microtexturing
5 An Analysis of Energy Consumption and Energy Efficiency in Material Removal Processes
5.2 Plant and Workstation Levels
5.4 Process Optimization for Energy Consumption
5.4.1 Plant Level and Workstation Level
5.4.2.1 Turning Operation
5.4.2.2 Milling Operation
5.4.2.3 Drilling Operation
5.4.2.4 Grinding Operation
6 Nontraditional Removal Processes
6.1.2.1 Electrical Discharge Machining
6.1.2.2 Electrochemical Machining
6.1.2.3 Electrochemical Discharge Machining
6.1.2.4 Electrochemical Grinding
7 Surface Treatment and Tribological Considerations
7.2 Surface Treatment Techniques
7.2.1 Surface Geometry Modification
7.2.2 Microstructural Modification
7.2.3 Chemical Approaches
7.3.3 Miscellaneous Coating Operations
7.5 Evolving Technologies
7.5.1 Biomimetics – Biologically Inspired Design
8.2 Sustainability in Joining
8.5 Efficiency of Joining Equipment
8.6 Efficiency of Joining Processes
8.6.2 Chemical Joining Methods
8.6.3 Solid-State Welding
8.6.4 Mechanical Joining Methods
8.6.4.1 Mechanical Fastening
8.8 Efficiency of Joining Facilities
8.9.1 Submerged Arc Welding (SAW)
8.9.2 Friction Stir Welding (FSW)
9 Manufacturing Equipment
9.3 Characterizing the Power Demand
9.5 Life Cycle Energy Analysis of Production Equipment
9.6 Energy Reduction Strategies
9.6.1 Strategies for Equipment with High Processing Power
9.6.2 Strategies for Equipment with High Tare Power
9.7 Additional Life Cycle Impacts of Energy Reduction Strategies
10 Energy Considerations in Assembly Operations
10.1 Introduction to Assembly Systems & Operations
10.2 Fundamentals of Assembly Operations
10.3 Characterizing Assembly System Energy Consumption
10.4 Direct Energy Considerations of Assembly Joining Processes
10.4.1 Mechanical Assembly
10.4.3 Welding, Brazing, and Soldering
10.5 Assembly System Energy Metrics
10.6 Case Study: Heavy Duty Truck Assembly
10.6.1 Case Study Energy Consumption Analysis Approach
10.6.2 Assembly Process Categorization
10.6.3 Case Study Energy Analysis Results
10.6.4 Discussion and Recommendations
10.7 Future of Energy Efficient Assembly Operations
11 Manufacturing Facility Energy Improvement
11.2 Auxiliary Industrial Energy Consumptions
11.2.1.1 Lighting Technologies
11.2.1.2 Opportunities for Improving Energy Efficiency of Industrial Lighting
11.2.2.2 HVAC Energy Efficiency Opportunities
11.2.3.1 Compressed Air Technologies
11.2.3.2 Improving Energy Efficiency of Air Compressors
11.3 Industrial Practices on Energy Assessment and Energy Efficiency Improvement
11.3.1 Types of Energy Assessments
11.3.2 Energy Assessment Procedures
11.4 Energy Management and Its Enhancement Approaches
11.4.1 Energy Management Description and Benefits
11.4.2 Establishing an Energy Management Approach
12 Energy Efficient Manufacturing Process Planning
12.2 The Basics of Process Planning
12.2.1 Types of Production
12.2.2 Process Planning Procedure
12.2.3 Process Planning Methods
12.3 Energy Efficient Process Planning
12.3.1 Energy Consumption and Carbon Footprint Models of Manufacturing Processes
12.3.2 A Semi-Generative Process Planning Approach for Energy Efficiency
13 Scheduling for Energy Efficient Manufacturing
13.2 A Brief Introduction to Scheduling
13.2.1 Machine Environments
13.2.2 Job Characteristics
13.3.3 Feasible Schedules and Gantt Charts
13.2.4 Objective Functions: Classic Time-Based Objectives
13.3 Objective Functions for Energy Efficiency
13.4 An Integer Linear Program for Scheduling an
Energy-Efficient Flow Shop
13.4.1 A Very Brief Introduction to Mathematical Optimization
13.4.2 A Time-Indexed Integer Linear Program for the Energy-Efficient Flow Shop Problem
13.4.3 Algorithms for Solving Integer Linear Programs
13.5 Conclusion and Additional Reading
14 Energy Efficiency in the Supply Chain
14.1 Supply Chain Management
14.2 Supply Chain Structure
14.3 Supply Chain Processes
14.3.1 Customer Relationship Management
14.3.2 Supplier Relationship Management
14.3.3 Customer Service Management
14.3.5 Manufacturing Flow Management
14.3.7 Product Development and Commercialization
14.3.8 Returns Management
14.4 Supply Chain Management Components
15 Business Models and Organizational Strategies
15.2 Reference Framework for Selection of Energy Efficiency Projects
15.2.1 Mission and Drivers
15.2.2 Set Level of Assessment
15.2.3 Recognize Opportunities and Risk
15.2.5 Implementation and Communication
15.3 Common Energy Efficiency Opportunities
15.3.2 Heating, Ventilation and Air Conditioning (HVAC)
15.3.3 Efficient Lighting
15.3.4 Efficient Motors and Systems
15.3.5 Building Management Systems
15.4.1 Tenants and Owners
15.4.4 Energy Service Companies (ESCOs)
16 Energy Efficient or Energy Effective Manufacturing?
16.1 Energy Efficiency: A Macro Perspective
16.1.1 Government Perspective
16.1.2 Company Perspective
16.2 The Basics of Energy Efficiency
16.3 Limitations of Energy Efficiency
16.4 Energy Effectiveness
16.4.1 Effectiveness – It’s Up to the Decision Maker
16.4.2 Effectiveness – A Choice on Where to Invest
16.4.3 Effectiveness – Is An Action Really Worthwhile?
Energy Efficient Manufacturing
：Theory and Applications
Disclaimer: Any content in publications that violate the sovereignty, the constitution or regulations of the PRC is not accepted or approved by CNPIEC.
