Optimized design of press frames with respect to energy efficiency

Abstract Large forming presses require great amounts of construction metal materials. Nevertheless, eco-design principles in the field of forming presses have seldom been confronted in the scientific literature. In this paper, an optimization model is proposed, suitable for designing press frames which are optimal in terms of energy efficiency. First, a framework is proposed for modular and functional description of a machine tool is described, in order to identify the largest energy consuming modules and functions. Then, a simple analytical model of loads, stresses and deformations is proposed for pre-stressed structures. Then, the equations of the analytical models are used as the constraints of a numerical global optimization algorithm, aimed at minimizing the amount of energy stored into the press frame and the extra-energy due to deformation of the columns in the usage lifetime of the press. The results clearly show that, only if the press frame structure is monolithic, it is possible to obtain a solution which is truly optimal. This conclusion is robust with respect to potential noise or uncertainty issues, which in this case are mainly related to the coefficient of the objective functions.

[1]  Markus Wabner,et al.  Lightweight components for energy-efficient machine tools , 2011 .

[2]  Zhu Shu,et al.  A novel approach of preparing press-powders for cleaner production of ceramic tiles , 2010 .

[3]  Julian M. Allwood,et al.  Sustainable Materials - With Both Eyes Open , 2012 .

[4]  Yan He,et al.  An on-line approach for energy efficiency monitoring of machine tools , 2012 .

[5]  Zhi Dong Duan,et al.  Topological Optimization of Frame of High Speed Hydraulic Press Based on Generalized Finite Element Modules , 2010 .

[6]  Fernando Gomes de Almeida,et al.  Improving the environmental performance of machine-tools: influence of technology and throughput on the electrical energy consumption of a press-brake , 2011 .

[7]  Huai Gao,et al.  A modeling method of task-oriented energy consumption for machining manufacturing system , 2012 .

[8]  Paul Xirouchakis,et al.  Evaluating the use phase energy requirements of a machine tool system , 2011 .

[9]  Feng Lin.  KEY TECHNOLOGIES OF MODERN HEAVY DIE FORGING PRESS , 2006 .

[10]  Hans Albert Richard,et al.  Fatigue crack propagation in the frame of a hydraulic press , 2008, CP 2013.

[11]  Sergio Baragetti,et al.  Costruzione di Macchine 1 , 2007 .

[12]  Joost Duflou,et al.  Environmental Performance of Sheet Metal Working Processes , 2011 .

[13]  Tomaz Rodic,et al.  A combined approach to determine workpiece-tool-press deflections and tool loads in multistage cold-forging , 2011 .

[14]  Michele Monno,et al.  Optimization of Pre-Stressed Press Frames , 2012 .

[15]  Zhicheng Huang.  Study on the impact of energy consumption on the mainframe structure of two beam-type automatic hydraulic tile press , 2011, Proceedings of 2011 International Conference on Electronic & Mechanical Engineering and Information Technology.

[16]  Xu Hong Guo,et al.  Finite Element Analysis and Lightweight Research on the Bed of a Large Machine Tool Based on HyperWorks , 2011 .

[17]  Lin Hua,et al.  Modeling and optimization of a 10000kn fine blanking press frame , 2011, 2011 International Conference on Remote Sensing, Environment and Transportation Engineering.

[18]  Jessica Lagerstedt,et al.  EcoDesign and The Ten Golden Rules: generic advice for merging environmental aspects into product development , 2006 .

[19]  Shi-Hong Zhang,et al.  Hydroforming Highlights: Sheet Hydroforming and Tube Hydroforming , 2004 .

[20]  Renji Zhang,et al.  Finite element analysis of the prestress wire-winding press , 2004 .

[21]  Fabrice Mathieux,et al.  DESIGN FOR ENERGY EFFICIENCY: PROPOSITION OF A GUIDELINES-BASED TOOL , 2010 .

[22]  H. B. Yu,et al.  Study on Mapping of Forming Precision of Workpiece to Stiffness of Hydropress Frame , 2011 .