Integration of Energy Oriented Manufacturing Simulation into the Life Cycle Evaluation of Lightweight Body Parts

Antal Dér*, Alexander Kaluza, Lars Reimer, Christoph Herrmann, Sebastian Thiede

*Corresponding author for this work

Research output: Contribution to journalArticleAcademicpeer-review

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Abstract

Recent years introduced process and material innovations in the design and manufacturing of lightweight body parts for larger scale manufacturing. However, lightweight materials and new manufacturing technologies often carry a higher environmental burden in earlier life cycle stages. The prospective life cycle evaluation of lightweight body parts remains to this day a challenging task. Yet, a functioning evaluation approach in early design stages is the prerequisite for integrating assessment results in engineering processes and thus allowing for a life cycle oriented decision making. The current paper aims to contribute to the goal of a prospective life cycle evaluation of fiber-reinforced lightweight body parts by improving models that enable to predict energy and material flows in the manufacturing stage. To this end, a modeling and simulation approach has been developed that integrates bottom-up process models into a process chain model. The approach is exemplarily applied on a case study of a door concept. In particular, the energy intensity of compression molding of glass fiber and carbon fiber sheet molding compounds has been analyzed and compared over the life cycle with a steel reference part.

Original languageEnglish
Pages (from-to)899-918
Number of pages20
JournalInternational Journal of Precision Engineering and Manufacturing - Green Technology
Volume9
Early online date3 Jan 2022
DOIs
Publication statusPublished - May 2022
Externally publishedYes

Keywords

  • Compression molding
  • Energy oriented manufacturing simulation
  • Life cycle evaluation
  • Lightweight body parts
  • Sheet molding compound

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