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A comparative assessment of energy demand and life cycle costs for additive- and subtractive-based manufacturing approaches
Full text linkThe applicability domain of Additive Manufacturing (AM) processes, apart from technological and quality results, relies on environmental and cost performance. These aspects still need to be better understood. To this aim, comparative analyses with conventional manufacturing routes are needed. In this paper, empirical cost and energy requirement models are suggested to assess subtractive- (machining) and additive- (Electron Beam Melting) based manufacturing approaches for the production of Ti-6Al-4V components. A life-cycle perspective is adopted, and all the steps from the input material production to the post-AM processing operations and the use phase are included. The analyses have been carried out considering the shape of the component, the light-weighting capabilities and the utilization time as the main factors of influence. The proposed modelling effort has allowed different decision-support charts, which are suitable for identifying the most energy-efficient or economically-advantageous manufacturing approach, to be obtained. The results have revealed that, for the considered case study, EBM could be a more energy-efficient approach than conventional machining, even without re-designing the component, due to the higher efficiency in raw material usage. As far as cost is concerned, the additive-based approach only becomes the preferable solution when the cost savings during the use phase are accounted for
The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components
Full text linkAdditive manufacturing (AM) processes allow complex geometries to be produced with enhanced functionality, but technological challenges still have to be dealt with, in terms of surface finish and achieved tolerances. Among the consolidated powder-bed fusion processes, electron beam melting (EBM), which allows almost stress-free parts to be manufactured with a high productivity and minimum use of support structures, suffers from a poor surface quality. Thus, finishing processes have to be performed. The same geometrical complexity, which is considered one of the benefits of AM, becomes an issue when finishing is applied, in particular when internal features are present. Unconventional isotropic superfinishing processes could be a solution to this problem since they can generate a low surface roughness on complex geometries. However, the performance characteristics, with regard to the environmental sustainability and economic aspects, need to be evaluated since they are key factors that must be considered for decision-support tools when selecting a finishing process. The technological feasibility of the isotropic superfinishing (ISF) process, applied to Ti-6Al-4V parts produced by electron beam melting, is investigated in this paper by considering the dimensional and geometrical deviations induced by the finishing treatment, and from observations of the surface morphology. A significant reduction in surface roughness, Sa, to around 4 μm, has been observed on the most irregular surfaces, although the original shape is maintained. Environmental sustainability has been analyzed for all the manufacturing steps, from powder production to part fabrication, to the finishing process, and both the cumulative energy demand and material waste have been accounted for. The economic impact of the whole manufacturing chain has been evaluated, and the advantages of the ISF process are pointed out
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