1. Energy and Ressource Efficiency in
Production
Seminar “Produceer met minder energie”
Dipl.-Ing. Ralf Schlosser,
Sirris Zwijnaarde, 08.11.11
© WZL/Fraunhofer IPT

2. Agenda
1 Presentation WZL
2 Motivation
3 Assessment of energy- and resource consumption within the BEAT Project
4 Industrial Case Studies and Application of Sustainable Manufacturing
5 Summary
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3. RWTH Aachen and Fraunhofer-Gesellschaft
Fraunhofer-Gesellschaft
 More than 80 institutes und facilities
at 40 locations in Germany
 18,000 employees
 approx. € 1.65 billion research funds
per year, € 1.4 billion through research contracts
 3 institutes in Aachen
RWTH Aachen University
 Founded in 1870
 33,000 students
Faculty of Mechanical Engineering
 8,700 students
(incl. 1,800 first year students)
 54 professors
 2,600 employees
 140 graduates per year
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4. Production Technology in Aachen
Laboratory for Machine Tools
and Production Engineering (WZL)
 RWTH Aachen University institute
 Founded in 1906
 720 employees
 16,000 m² offices and laboratories
Fraunhofer Institute for Production Technology IPT
 Fraunhofer-Gesellschaft institute
 Founded in 1980
 365 employees
 3,000 m² offices and laboratories
 Certified to DIN EN ISO 9001:2000
 Partner in Boston/USA:
Fraunhofer Center for Manufacturing Innovation CMI
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5. Process and Manufacturing Technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. mult. Fritz Klocke
Cutting Grinding and forming Laser machining CAx Process and
technology technologies product
monitoring
Turning, Grinding, Solid forming, Joining, Laser surface Rapid CAD/CAM Process moni- Material
milling, lapping, sheet metal cutting, treatment Manufacturing technologies toring systems removal
drilling, polishing, forming, hard forming and strategies processes
broaching honing smooth rolling,
tribology
Tool and die making
Precision and micro technology
Optics and optical systems
Plant engineering and construction
Automotive, aerospace, turbine construction
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6. Chair of Manufacturing Technology −
Cutting Technology Department
Prof. Dr.-Ing. Dr.-Ing. E.h.
Dr. h.c. Dr. h.c. Fritz Klocke
Fritz Klocke
Dipl.-Ing. Dieter Lung
Chiefengineer
Dr.-Ing. Dipl.-Ing.
Klaus Ralf Schlosser
Gerschwiler
Modeling and Evaluation
Basics of Cutting of
Cutting Processes
 Process and Process strategy  Cutting durability tests  Process model development  Energy-/Ressourceefficiency
development  Cutting Simulation  Energetical Evaluation of
 Metallographic
 Machinability investigations Investigations  Calculation of the influence on cutting processes
the work piece  Ecological
 Lubricoolant Supply
 Micro cutting Lifecycle Management
Strategies  Technology-Research Circle
 6 Phd Students  7 Technicians  4 Phd Students  2 Programmer
 1 Post Doc  1 Post Doc  1 Apprentice
Tribology Processanalysis Tooldevelopment Microtechnology
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7. Agenda
1 Presentation WZL
2 Motivation
3 Assessment of energy- and resource consumption within the BEAT Project
4 Industrial Case Studies and Application of Sustainable Manufacturing
5 Summary
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8. Motivation: Social and ecological boundary conditions
Population growth Resource availability
8 2025
Coal
7
World population /bil.
4 bilions in 50 years
Natural gas
6
5
Crude oil
4 1975 Uranium
3 2 bilions in 45 years Iron
2 1930
1 bilion in 80 year Copper
1 1850
500 Mio. in 200 years 1650
Zinc
0
1 500 1000 1500 2000 Years 50 100 150 200
Year
Source: J.Jeswiet, Bundesanstalt für Geowissenschaften und Rohstoffe 2000
For the future demand of the growing world population more products
have to be manufactured with less energy and resources.
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9. Press hardening of car bodies shown on the example of an Audi A4
Press hardened steels  Press hardened steel provides higher strength
Conventional, high- in comparison to cold-formable steels and
strength and multilayer applications
ultrahigh-
strength  Improved crash characteristics
steels  Car body weight reduction of 9 kg
20 15
Change on the CO2
-equivalent / kg/car
0
 Positive carbon footprint already during product
manufacturing – environment-friendly before roll- -20
out -19
-40
Higher body strength -60 -53 -57
leads to weight reduction and to Production Total
a positive carbon footprint Material- Usage
production
Source: AUDI AG
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10. Life Cycle Assessment along the product life cycle
 Determination of material and energy
Energy Waste flows for all life cycle phases (according to
Raw material DIN EN ISO 14040)
Resource extraction Emissions
Energy Waste  Calculation of environmental impacts
(scientifically based characterisation
Resource Production Emission factors)
Energy Waste  Potential reduction of energy and material
consumption in 2 ways:
Resource Use Emissions – Identification of „hot spots“ → saving
options can be deduced
Energy Waste – Better understanding and comparability of
material and energy consumption for
Resource Recycling/ Emissions different machining processes
Disposal
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11. Energy and tool costs in a cylinder head production
Costs Energy
250
200 24,2%
Costs / %
150 57,3%
18,5%
100
50
0 Cooling lubricant
2000 2001 2002 2003 2004 2005 2006 2007
Cleaning
Costs for electrical energy Tool costs Machining
Source: Volkswagen
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12. Agenda
1 Presentation WZL
2 Motivation
3 Assessment of energy- and resource consumption within the BEAT Project
4 Industrial Case Studies and Application of Sustainable Manufacturing
5 Summary
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13. BMBF-Project BEAT:
Assessment of energy efficiency of alternative processes and technology chains
Aims
 Classification of manufacturing processes
 Identification of inefficient processes
 Holistic life cycle assessment of alternative
processes and process chains
Our proceeding
 Identification of the relevant balance shell
 Detection of material and energy flows in
manufacturing processes
 Definition of criteria to evaluate the energy and
resource efficiency of manufacturing processes
Pictures: FhG, WZL, Daimler, Bosch
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14. Chart of the energy and resource flows within gear manufacturing
 Machine tools as the relevant balance shell for
the evaluation
 Detection of all input and output quantities
along the whole process chain
 Multiple energy and material flows
 Detection of central installations for process
media supply
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15. Section of the energy and material flow chart
Indirect layer Direct layer
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16. Evaluation of the direct electrical energy flows in valve injectors
Average power consumption Energy per part
Turning
Washing
Heat treatment
Eroding
Rounding
Flow rate check
Laser marking
Grinding
Deburring
Optimisation of the highest power consumers
doesn’t necessarily bring the best benefit.
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17. Intermediate Summary
 The energy per functional unit (per part) is not only dependent from the average power
consumption of a process
 Main influencing factors are also the manufacturing time and amount of parallel
processed workpieces
 Further investigation in the Projects BEAT will also discuss the topics:
– Energy efficiency map of cutting processes
– The effect of indirect energy by peripheral units as air conditioning, central lubricoolant supply,
central compressed air units
– Holistic Life Cycle Assessment of all material and energy flows in the single processes and the
complete process chains within the GABI Software
www.beat-bmbf.de
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18. Agenda
1 Presentation WZL
2 Motivation
3 Assessment of energy- and resource consumption within the BEAT Project
4 Industrial Case Studies and Application of Sustainable Manufacturing
5 Summary
© WZL/Fraunhofer IPT Seite 18

19. Energy efficiency by process substitution
Coil Gap part Integrated Die forging Die forging Die forging Blank
production shearing heating I II III shearing
Gap part
Local
Coil Route Blade
heating and Die forging
production shearing shearing
compressing
Punch
Route Forged scrap
bolster
Finished
part
Short process chains reduce work in progress inventory, the processing
time, energy consumption per part and increase the process safety
Source: Zwilling J.A Henckels AG
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20. Optimized machining strategy for the manufacturing of lubricating
bores in cylinder heads
Lubricating bore:
Machining time t/min
10 8.71
 borehole depth: l = 520mm
-80%
5  bore diameter: d = 7mm
1.74
1,74
 aspect ratio: l/d = 74
0
Old New
Tool concept Essential approach:
Old tool concept: New tool concept: Spiral  expanding the application of
HSS - Single-lip drill solid carbide drill solid carbide drills!
Conclusion:
 process time reduction
leads to essential energy
cutting parameters cutting parameters saving
f = 0.035 mm f = 0.23 mm
Source: MAN Diesel & Turbo
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21. Increase in productivity by dry machining
status 2006 yesterday today tomorrow
Cutting material HSS-PM HSS-PM HM
coating
cutting speed. vc / m/min
feed fa / mm
AlCrN
90
4
AlCrN
150
4
AlCrN
240
3
?
max. chip thickness / mm 0.24 0.24 0.18
7
Wet machining Dry machining
Time per part /min
6
5 Continuous improvement
Leap in technology
4
3
2
1
0
1999 2002 2005 2006 yesterday today tomorrow
Source: Daimler AG
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22. Exhaust gas heat recovery
Ring hearth furnace Ring hearth furnace with heat recovery
Technical heat
network
heat reflow
consumer i
consumer …
heat input
 960° C process temperature  Heat exchanger installation on burner
exhaust gas line, furnace cooling not yet
 60m³ natural gas/ h → 120 kg CO2/ h
used
 Technical heat generation only by gas
 Approx. 60 KW can be continuously fed
back into the energy network
Transparency creates simple optimization potentials
Source: Daimler AG
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23. Energy saving potentials in machines and plants
Inflexible machine und plant Machine ventilation Adaptable
ventilation machine- und plant ventilation
 Necessary ventilation  50% energy reduction for
power is predefined by machine and plant
machine manufacturer 1800 m³/h 720 m³/h ventilation through flexible
installations
 Oversized and not
adaptable plant ventilation Plant ventilation  Integration of flexible
>30 Nm³/(m².h) machine and plant
 Regulation of machine
ventilation into the
and plant ventilation is not
requirements
considered in the design
17 Nm³/(m².h)
Status before Status after
Adaptable and flexible central installations
Source: Daimler Trucks
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24. Use of water in the automobile production
Water consumption within the BMW Group 2009: 3.2 Mio m³
Sanitary waste water
Drinking water
Evaporation
Process waste water
Ground Water
Source: BMW Group 2011
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25. Use of water in the automobile production
Reduction of consumption of sanitary water
Picture: bau-web.de
Water consumption of a conventional tap:
4 l water, 24 s runtime
10
Flow rate /(l/min)
8
6
4
2
0 Time /s
0 2 4 6 8 10 12 14 16 18 20 22 24
Water consumption of a sensoral tap:
2.2 l water, 15 s runtime
10
Flow rate /(l/min)
8
Sensors within taps reduce the average 6
water consumption during hand washing 4
about 45% 2
0 Time /s
0 2 4 6 8 10 12 14 16 18 20 22 24
Source: BMW Group 2011
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26. Resource saving by reconditioning instead of recycling
 Serial reconditioning of
starters and generators
 Annual savings compared
to production of new
components:
– 85.000 MWh energy =
Starter and generators Fuel injection/ignition
88% savings compared to
Disassembling Assembly new production
Replacement Exchange
“Back in Box” + +
of wear parts product 200.000 kg Copper
Cleaning Final check
350.000 kg Aluminium
Distributor pump Fuel-injector-mount combination
1.600.000 kg Steel
58.000 kg CO
800.000 kg CO2
4.300 kg SO2
Source: Bosch
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27. Agenda
1 Presentation WZL
2 Motivation
3 Assessment of energy- and resource consumption within the BEAT Project
4 Industrial Case Studies and Application of Sustainable Manufacturing
5 Summary
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28. Acknowledgements
We kindly acknowledge the support of the Project BEAT by
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