Green ManufacturinggEfficiency of Products and Processes –Innovative Manufacturing of Resource-efficient ProductsHans-Jörg BullingerFraunhofer-Gesellschaftwww.fraunhofer.de

© Fraunhofer

The Profile of Fraunhofer

7 Groups:60 InstitutesInformation and Communication TechnologyLife Sciences

more than 18,000 employees

MicroelectronicsLight & Surfaces Production

about 1,65 billion €research budget

Materials and Components – MATERIALSDefense and Security

© Fraunhofer

Motivation for the introduction of a resource-efficient manufacturing 180

OIL180

ELECTRICITY0) )

120

140

160

OIL

120

140

160

ELECTRICITY

ndex

(200

0=10

0

dex

(200

0=10

0)

80

100

120

80

100

120

Impo

rt pr

ice

in

mpo

rt pr

ice

ind

160

180STEEL

2001 2003 2005 2007

160

180WATER

Year

I

Year2001 2003 2005 2007

000=

100)

100)

100

120

140

100

120

140

r pric

e in

dex

(20

e in

dex

(200

0=1

2001 2003 2005 2007

80

Bildquelle:

80

2001 2003 2005 2007

Pro

duce

r

Year

Pric

e

YearSource: Destatis, Deutsche BP, E.ON, Statistisches Landesamt BW, ThyssenKrupp

© Fraunhofer

Source: Destatis, Deutsche BP, E.ON, Statistisches Landesamt BW, ThyssenKrupp

Energy and tool costs in a cylinder head production

200

250

150

200

s / %

50

100Cos

ts

02000 2001 2002 2003 2004 2005 2006 2007

Costs for electrical energy Tool costsSource: Volkswagen

© Fraunhofer

Source: Volkswagen

Influencing factors on the industrial production

Business objectives EnvironmentMarket

ProfitSustainability

GlobalisationIncrease in consumption of

Scarcity of resourcesIncrease of disposal costsSustainability

CompetitivenessIncrease in consumption of resources

Increase of disposal costs Environmental damage

IndustrialPolitics and society Legislation and j i di tiproduction

Politics and society jurisdiction

Consumer awarenessSocial responsibilityChange in political objectives

Prescription and tightening of critical valuesLegal restraintsChange in political objectives Legal restraintsConsequences of the law

© Fraunhofer

Resource-efficient production – the production chain as a focus

Energy SuppliesTools

Component/productGrindingMilling

Anneal-ing Assembly

Support processes

FormingSemi-finishedpart/ material

Support processes

R id l t i l EmissionsResidual materialschips, effluent,

sludgeScrap

Emissionsheat, noise, vapours,exhalation, vibrations

Source: IWT Bremen, Kutz + Schulz, ThyssenKrupp

© Fraunhofer

Source: IWT Bremen, Kutz Schulz, ThyssenKrupp

Resource saving by process modification and –substitution in bevel gear manufacturing

Conventional process chainConventional process chain

Forging

Soft turning,drilling, tappingwith coolinglubricant

Gear cuttingwith

lubricationCase hardening

Grindingwith

cooling lubricantGear lapping Screwing

Forging

Soft turning,drilling, tappingwith cooling

Gear cuttingwith

l b i tiCase hardening

Grindingwith

li l b i tGear lapping Screwing

Optimisation step1.

Hard turning

2. Optimisation step

Gear cuttingdry

Dry gearcutting

3. Optimisation step 3.

Soft turningwith coolingl b i t

WeldingSoft turningwith coolingl b i t

WeldingHard turningwith coolinglubricant lubrication cooling lubricantdry

Wet machining:Cutting material: HSS

cutting

Elimination lubrication/ year

Dry machining:Cutting material: VHM

New process parameters:Feed f

lubricantlubricant

Coating: TiNy

ca. 25.000 l Coating: TiAlN Cutting speed vc

Elimination cooling lubricant Screwing of crown wheel : P d illi d t i

Welding of crown wheel : P Eli i ti f d illi dsystem, consumption/ year

Energy: 1,15 Mio. kW/hMedium: 1052 m³Filter fleece: ca. 45 t

- Process drilling and tapping- central cooling lubricant system

- Process Elimination of drilling and tapping

- Elimination of a central cooling lubricant system

Source: BMW

© Fraunhofer

Source: BMW

Resource saving by reconditioning instead of recyclingSerial reconditioning ofSerial reconditioning of starters and generators

Annual savings compared to production of new

Fuel injection/ignitionStarter and generators

to production of new components:

– 85.000 MWh energy = 88% savings compared to

Distributor pump Fuel-injector-mount combination

new production 200.000 kg

350.000 kg

Copper

Aluminium

“Back in Box”Disassembling

+Cleaning

Replacementof wear parts

Assembly +

Final check

Exchangeproduct

Distributor pump Fuel injector mount combination 1.600.000 kg

58.000 kg

800.000 kg

Steel

CO

CO2800.000 kg

4.300 kg

CO2

SO2

Source: Bosch

© Fraunhofer

Source: Bosch

Energy and tool costs in a cylinder head production

250

Costs Energy

150

200

ts /

%

24,2%

18 5%57,3%

50

100Cos

t 18,5%

0

50

2000 2001 2002 2003 2004 2005 2006 2007Cooling lubricantCleaning

Costs for electrical energy Tool costsCleaningMachining

Source: Volkswagen

© Fraunhofer

Source: Volkswagen

Demand driven thinking: Green automobile productionGreen Carbody Technologies Green Powertrain Technologies

Resource efficiency in the process chain„coated body“

Goal GoalAdadaptive

Formhonstrategy

„From the Motor to the Wheel“

Tool making

Press plant

Body manufact. Coat

Press plant: - Reject (< 2 %)- Utilization of material (> 75 %)

Body manufacturing:Energy consumption (um 20 %)

CO2-Emissions 20 %- Efficiency 5 %

(through friction power minimization)- Light construction- Energy consumption (um 20 %)

- Stand-by-losses (um 50 %)

Innovation-AlliancePlanning

Cam shaft: 50 % weight Con rod: 20 % weight Crank shaft: 25 % weight

Lead projectsTool makingPress plantBody manufacturingCoating

Lead projectsLow energy motorLight construction transaxleElectric-Traction

© Fraunhofer

g

Fraunhofer IWU, IPT, IPA, 62 companies

Air diverter Cooling lubricantShoe injector

Resource saving by adapted lubrication injectionAir diverter Cooling lubricantShoe injector

Schleif-scheibeGrinding

disc

Needle injectorNeedle injector

Source: Grindaix

© Fraunhofer

Source: Grindaix

Effects of lubrification and coatings on the tool wear behaviour in drilling of Inconel 718

TiAlN/WC/C

Synthetic ester without additives

nl-TiN/TiAlN

Emulsion

200

250

B /

µm uncoated TiAlN/WC/C

100

150

200

wea

r lan

d VB

nl-TiN/TiAlN

ml-TiAlN/γ-Al2O3

50

0

100

Wid

th o

f fla

nk

ml-TiAlN/γ-Al2O3

Number of holes0 20 40 60 80 100 120

Number of holes0 20 40 60 80 100

0W

Material: Inconel 718Process: centre drillingDrill depth: l = 17 mmml: multilayer, nl: nanolaminate

Cutting parameter :vc = 20 m/minf = 0,09 mm

Cooling lubricants:Emulsion 6%Synthetic ester without additives

Drill:substrate: HW-K20d = 6,8 mm

© Fraunhofer

Three steps towards implementation of a resource-efficient production

Material flow– Working plans

ERP S

Identification of resource-intensive processes– ERP – System

Use of Supplies

Energy consumption

processes

Generation of environment- and resource-ratiosgy p

– Location-based– Department-based – Process-based

resource-ratios

Efficiency analysis of the resource-intensive processes

Each action is process specific

© Fraunhofer

Data acquisition and generation of ratios by the tool Resource Cost Accounting RCA

1. Analysis of the current state of the business process

2. Formulation of potentials and aims

3. Generation of necessary structures for data acquisition

4. Generation of RCA: Input – Output calculationBenefits for the company and the environment:

Transfer of relevant information in an i t t d t lli

5. Ratio generation: Evaluations and reports

6. Implementation in the decision process

integrated controlling

Identification of cost drivers

Generation of optimization approaches

Addi lp p

7. Deriving and controlling actions

Adding value

Expansion of existing operational planning and cost calculation with the aim to increase the resource productivity

Source: Effizienz-Agentur NRW

© Fraunhofer

Source: Effizienz Agentur NRW

Energy consumption in manufacturing and life cycle

Production Products – service life

Small lever Large effects

Energy consumption inservice life

Energy demand in production

service life

Manufacturing alternative 2

Manufacturing alternative 1

g

Energy consumption in product life cycle: Eges1 >> Eges2

© Fraunhofer

Functionality of riblets

Resource savings by surface designFunctionality of riblets

Vortex

Large-eddy simulation (LES)Ma Turbulent vortexes are kept away from the surface so that wall friction is reduced

Shark skinwith riblets

Riblets can theoretically reduce the wand friction and also wall resistance up to 10%

Sawtooth riblets

Source: Boeing, DB, MTU, Rolls Royce

© Fraunhofer

Source: Boeing, DB, MTU, Rolls Royce

Functionality of riblets

Innovative process for the production of riblet structureson compressor blades

Functionality of riblets

Vortex

Large-eddy simulation (LES)Ma Turbulent vortexes are kept away from the surface so that wall friction is reduced

Shark skinwith riblets

Riblets can theoretically reduce the wand friction and also wall resistance up to 10%

Sawtooth riblets

Shotpeeningturbineblade

Massiveforming

Investmentti

Millingdove tail

Basic rawmaterial(TI6Al)

ECM

Millingbl d t bladecasting blade root

Rollingriblet

Source: Leistritz Turbomaschinen Technik, MTU, ThyssenKrupp

© Fraunhofer

Source: Leistritz Turbomaschinen Technik, MTU, ThyssenKrupp

Assessment of resource consumption withEnvironmental Product Lifecycle Management

ect

stru

ctur

eP

rodu

c

Labour costsManufacturing

Machine enclosure Cost element

Source: IEC

© Fraunhofer

Source: IEC

Assessment of a tool changer in machine tools

Sum

PT

Packaging

PT

Hydraulic/ pneumatic

PT

Machine enclosure

PT

Coolant system

PT

Tool changer PT

Head

PT

Z-Module

PT

Y-Module

PT

X-Module

PT

45719,3479,23137,0113,82417,1814,815073,03427,09116,711140,7

%Eco-Points

PTEco-Indicator

PTInputs/OutputsActivityLife cycle phase UnitAmount

3,730,10,086C45MaterialRaw material manufact.3,125,20,0241 Truck (24t)Transport (3000km)Logistics0,75,80,026ElectricityEnergy consumptionManufacturing

91,9748,80,026ElectricityEnergy consumptionUse and maintenance

3501050224

kgtkmkWh

28800 kWh350 kg 0,64,90,014C45MaterialDisposal

100814,8Sum

© Fraunhofer

Summary:Targets for resource-efficient production

Resourcescarcity

Increased globalIncreased globaldemand

Increase in resourceprices

Selective use ofresources in

product life cycle

Resource-efficientproduction

Resource intensiveResource intensive manufacturing forresource savings

in service life

Minimal use ofresources in the entire

product life cycleSource: Airbus, Stahlwille

© Fraunhofer

Source: Airbus, Stahlwille

GreenGreen

© Fraunhofer