Manufacturing impact assessment for remanufacture of a forging die

Appleby, Andrew and Reimer, Andreas (2023) Manufacturing impact assessment for remanufacture of a forging die. In: International Conference on Remanufacturing 2023, 2023-06-27 - 2023-06-29, RAI.

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Abstract

Methods to reduce energy use and carbon emissions are of increasing interest and importance to manufacturers. Carbon pricing and environmental legislation is likely to make them even more so in the future. Remanufacturing (reman) has significant potential to reduce embodied energy and carbon emissions. To fully understand this impact, the savings must be measured. In addition, to make these values meaningful, they must be compared to a baseline (e.g., conventional manufacture (CM)). This paper presents a framework for manufacturing impact assessment, suitable for use in the manufacturing sector. The method is used in a case study of remanufacture of a forging die. The die was originally machined from H13 (a hot working tool steel) and reached end of life after 1300 cycles. During reman, the wear areas were rebuilt using laser metal deposition of Stellite 21 and, after machining, the die went on to operate for another 1400 cycles. A cradle-to-gate life cycle analysis (LCA) was carried out to compare the two methods. The model was challenging to develop because of the sparsity of available data available on additive and powder manufacturing processes. Despite this, the analysis considers the impact of the materials and processes used in both reman and CM routes, to give a robust comparison. The results show that the energy and CO2 eq. used in reman is a reduction of over 99% compared to the CM. It is reasonable to claim that, for other CM/reman cases of this type, results should be similar because the largest impact was the reduction in the quantity of material used.

ORCID iDs

Appleby, Andrew ORCID logoORCID: https://orcid.org/0000-0002-6678-3234 and Reimer, Andreas ORCID logoORCID: https://orcid.org/0000-0002-5115-9092;
CORE (COnnecting REpositories)