Reusable unit process life cycle inventory for manufacturing: metal injection molding
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PRODUCTION PROCESS
Reusable unit process life cycle inventory for manufacturing: metal injection molding Kamyar Raoufi1 · Dustin S. Harper1 · Karl R. Haapala1 Received: 4 August 2020 / Accepted: 13 October 2020 © German Academic Society for Production Engineering (WGP) 2020
Abstract Unit process life cycle inventory (UPLCI) is a modeling approach that enables researchers to estimate the energy use and material flow for a unit process. UPLCI models can be reused in characterizing a full manufacturing line, where a wide range of machines and materials are used. As part of a collaborative effort from various universities and industry researchers to create UPLCI models for all common manufacturing processes, this paper presents UPLCI for the metal injection molding (MIM) process, which is in the mass conserving category of the taxonomy of manufacturing processes. In addition to the energy required for injection molding of the metal-polymer feedstock and for the subsequent debinding and sintering processes, the energy consumption during idle and standby periods are also captured. The application of the UPLCI model for MIM process is demonstrated using an example case study. This UPLCI model provides opportunity for researchers to estimate the energy use for a sequence of manufacturing processes used to make a metal injection molded product. Keywords Metal injection molding · MIM · Process energy · Unit process · Unit process life cycle inventory · UPLCI Abbreviations COP Coefficient of performance LCI Life cycle inventory MIM Metal injection molding UPLCI Unit process life cycle inventory List of symbols Apart Projected area of the part cj Empirical constant cpm Heat capacity of the metal powder cpi Heat capacity of ith binder component dcl Clearance between mold and part dcav Depth of the mold cavity Eclamping Cooling energy consumption Ecool Cooling energy consumption Einjection Cooling energy consumption EMIM Injection molding (IM) energy use * Kamyar Raoufi [email protected] Dustin S. Harper [email protected] Karl R. Haapala [email protected] 1
School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, 204 Rogers Hall, Corvallis, OR 97331, USA
Emat_inj Material injection energy consumption Emelt Melting energy consumption Epack Packing energy consumption Ereset Resetting energy consumption Ebasic(IM) Basic energy for IM Etotal Total energy consumption per part Hcool Heat to be removed from the molded part Hfi Heat of fusion for the ith binder component Hm Heat of fusion for the metal powder hmax Maximum wall thickness of the part Ls Maximum clamp stroke of the machine m Mass of feedstock ncav Number of cavities in the mold pinj IM machine injection pressure Pbasic(IM) Basic power of IM machine Pinj IM machine injection power Qmax Maximum material flow rate Qavg Average material flow rate tbasic(IM) Basic IM time tcycle(IM) IM cycle time tc Cooling time tdry Dry time tdwell Dwell time ti Injection time tr Resetting
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