Life-Cycle-Management von Werkzeugen mit geometrisch unbestimmter Schneide mit besonderem Augenmerk auf Nachhaltigkeit, Energie- und Ressourceneffizienz
Final Report Abstract
Goals of this project are to understand sustainability of abrasive tools holistically, derive recommendations for greener designs, and publish the results. There is a need for a comprehensive and clear composition on abrasive tools, which is met with the habilitation thesis compiled within the project time. This work is intended to help tool users, manufacturers and students understanding the dimensions of sustainability in abrasive tooling systems. Sustainability indicators have been revised and appropriate indicators for grinding were proposed. A grinding process inventory was consolidated and shows the state of the art in research on the environmental impact of grinding, e.g. cooling lubricant is a central factor, but tooling, equipment, worker or part function should be investigated further. As abrasive machining processes are at the end of the process chain, they affect part function strongly. Trade-offs between manufacturing and product use need to be considered. For example, it might be beneficial to invest more into the abrasive machining process to increase product life time. This holistic perspective to sustainability in production engineering needs further research. For the first time, the embodied energy, i.e. energy for raw material processing and manufacturing, of grinding tools with vitrified bond was conducted. A newly developed axiomatic model of grinding analyzed the many complex functions of a grinding system. Some functions and design properties are conflicting, especially if energy, cost or waste reduction is demanded and part surface integrity should be constant. Ideas for more sustainable concepts for tool manufacturers are exemplified. The original work plan held more experiments, which were substituted with additional data mining and a broader incorporation of sustainability. There was few quantifiable data, but discussions with industry compensated for it and revealed industrial challenges. It seems that the U.S. industry is more confined to collaborate with academia than German industry, e.g. sample tools were not possible to get. The overall industrial response to the project was positive, although smaller companies fear that new labels might evolve. Being in the U.S. has broadened the scope of the project, diversified the available literature and induced new perspectives. The unique opportunity to interact with Professor David Dornfeld and his students was very productive and resulted in two joint journal publications. This project brings together existing knowledge about abrasive grits, bonding systems, pore builders, body material, and tool production and reprocesses the information with unified terminology. Information on social and environmental aspects of tool ingredients and manufacturing is added and gives a new understanding of tool sustainability. In the future, tool users and producers will be able to address these issues better. Furthermore, this review shows where emphasis is missing, e.g. environmental sustainability in tool use or social sustainability in tool end of life are barely regarded, but could provide a competitive edge to tool manufacturers.
Publications
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Combination of Speed Stroke Grinding and High Speed Grinding with Regard to Sustainability, Proceedings of the 44th CIRP International Conference on Manufacturing Systems, Madison, WI, USA, June 1 – 3, 2011
Linke, B.; Duscha, M.; Klocke, F.; Dornfeld, D.
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Application of Axiomatic Design Principles to Identify More Sustainable Strategies for Grinding, Journal of Manufacturing Systems, Vol. 31, Issue 4, October 2012, p. 412 – 419
Linke, B.; Dornfeld, D.
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Establishing Greener Products and Manufacturing Processes, International Journal of Precision Engineering and Manufacturing, July 2012, Volume 13, Issue 7, p. 1029 – 1036
Linke, B.; Huang, Y.-C.; Dornfeld, D.
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Life Cycle Analysis of Grinding, Proceedings of the 19th CIRP Conference on Life Cycle Engineering, Berkeley, CA, USA, May 23 – 25, 2012, p. 293 – 298
Linke, B.; Overcash, M.
