The Analysis of Energy Consumption of Stamping

Sheet metal stamping parts are widely used in automotive, aerospace, electrical and electronic industries due to their advantages of light weights, high strength, low raw material consumption and high production efficiency. In recent years, the output of automobile stamping parts in China has grown rapidly, from 33.05 million tons in 2010 to 46.2 million tons in 2015. However, the demand for forming force is great; the production cycle is fast, and the energy consumption is high. At the same time, the design requirements of lightweight products have promoted the application of lightweight and high-impact materials, including high-impact steel plates, aluminum alloys, magnesium alloys, and titanium alloys. Cold stamping cannot be used due to the poor formability of these materials, and heating is required to improve its formability. The use of hot stamping further increases the energy consumption of metal stamping. In recent years, scholars at home and abroad have gradually paid attention to the energy consumption and carbon emissions of metal stamping.
 
At present, the analysis of the energy consumption of stamping mainly adopts simulation, experiment and theoretical analysis to realize the quantification and evaluation of the energy consumption of sheet metal stamping. Ingarao G of the University of Palermo in Italy evaluated the material and energy consumption of the sheet metal stamping process from a sustainable perspective, and analyzed the energy and material consumption of the stamping under different process parameters. Plevy analyzed the influence of friction on the energy consumption in the drawing process, and pointed out that in the case of a relatively small mold gap, compared with the oil film lubrication, the use of solid polymer film lubrication can reduce the energy consumption in the drawing process. Jinwei Wang and others proposed that the friction at the entrance angle of the die can be reduced by using the cubic spline curve as the entrance angle curve of the die, thereby reducing the energy consumption of stamping. Gao and others established the energy consumption model and carbon emission model of each process and equipment in the stamping production line, analyzed the impact of various factors on carbon emission, and made corresponding low-carbon manufacturing suggestions. Fereshteh Saniee and others evaluated the requirements of the stamping force of typical parts through theoretical analysis, numerical simulation and experiments. Thiruvarudchelvan and others applied the positive ratio that the stamping force gradually increases with the increase of blank holder force, and combined the theory of deep drawing to predict the stamping force.
 
Hot stamping is an important way to realize the lightweight of the product. Materials such as high-impact steel and deformed magnesium alloys are widely used in the automobile manufacturing industry due to their many advantages. The traditional cold stamping process cannot meet the requirements of forming. Using hot stamping can effectively reduce the defects such as wrinkling and cracking of high-impact steel plate forming parts; as for forming lightweight magnesium alloys, hot stamping technology can improve their plastic forming properties. However, stamping needs to heat the blank to a certain temperature and then carry out processes such as forming, pressure holding, and quenching. Compared with the traditional cold stamping technology, energy consumption is significantly increased. Marco and others evaluated the environmental benefits of a new thermoforming technology used in the automotive industry through a life cycle assessment method, and the results showed that the additional energy consumption due to thermoforming can be compensated at the end of the life cycle of the material. Neugebauer and others optimized the hot stamping line to improve its resource and energy utilization. Ggschel and others proposed an energy and material balance method and applied it to the hot stamping process to monitor and characterize the energy and material flow in the manufacturing process. This method shows great potential in reducing scrap, speeding up production, and reducing the basic energy consumption of equipment.