PunchingProcessSummary.docVIP

MR 5 Punching Process Unit Process Life Cycle Inventory Dr. Devi Kalla, Dr. Janet Twomey, and Dr. Michael Overcash December 21, 2009 Punching Process Summary 2 Methodology for Unit Process Life Cycle Inventory Model 4 Punching Process Energy Characteristics 4 A. Parameters Affecting the Energy Required for Punching 6 Punching Energy 6 B. Method of Quantification for Mass Loss 12 Lci for Material Mass Loss Calculations 12 Lci for Lubricant Oil Waste Calculations 12 Tool set usage 12 Summary: 13 References Cited 13 Appendices 14 Manufacturers Reference Data 14 Punching Process Summary Punching is a frequent unit process in manufacturing as a mass reduction step, in which a scrap slug is separated from the workpiece when the punch enters the die. Hence this life cycle inventory is to establish representative estimates of the energy usage and mass loss from the punching unit process in the context of manufacturing operations for products. Punching is one of the widely used sheet metal forming operation in industries. The punching unit process life cycle inventory (uplci) profile is for a high production manufacturing operation, defined as the use of processes that generally have high automation and are at the medium to high throughput production compared to all other machines that perform a similar operation. This is consistent with the life cycle goal of estimating energy use and mass losses representative of efficient product manufacturing. Punching is a cutting process in which a punching machine separates a sheet of metal by striking it. Punching in terms of making holes or cutting out pieces is done by a process known as separating. Separating is the result of placing a sheet between an upper tool (punch) and a lower tool (die). The upper tool plunges into separating the sheet, producing a punching slug which is pushed through the lower tool. The scrap materials normally drop through a die and bolster plate into a container. The material being punched is usuall