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Engineering design shows a growing interest in exploring cost analysis to anticipate manufacturing issues and integrate production aspects within the product development process. This research aims to highlight key elements (inputs, parameters, models) to accurately predict the cost of a forged part using a complete model, with important information that can be available during the design phase. For this purpose, a systematic literature review of existing engineering methodologies developed for cost analysis of forged parts (i.e., cost estimation, DtC, and ABC) was performed with characterizations of the different approaches for evaluating the most important topics related to this objective. As a result, the most important insights related to the aim of this review are provided: (i) among quantitative methods, analytical and parametric models are the most suitable approaches to develop a cost estimation, (ii) a cost model based on a linear equation supported by single or multiple variables seems to be the most accurate tool to establish a robust cost analysis in the design of forged components, and (iii) input parameters related to the material type and geometrical features are the most critical cost-drivers in the cost assessment. Moreover, this review contributes to identifying emerging applications and obsolete topics, providing the ground to investigate unexplored areas relevant to future research.
Claudio Favi; Federico Campi; Marco Mandolini; Irene Martinelli; Michele Germani. Key features and novel trends for developing cost engineering methods for forged components: a systematic literature review. The International Journal of Advanced Manufacturing Technology 2021, 1 -25.
AMA StyleClaudio Favi, Federico Campi, Marco Mandolini, Irene Martinelli, Michele Germani. Key features and novel trends for developing cost engineering methods for forged components: a systematic literature review. The International Journal of Advanced Manufacturing Technology. 2021; ():1-25.
Chicago/Turabian StyleClaudio Favi; Federico Campi; Marco Mandolini; Irene Martinelli; Michele Germani. 2021. "Key features and novel trends for developing cost engineering methods for forged components: a systematic literature review." The International Journal of Advanced Manufacturing Technology , no. : 1-25.
Marco Mandolini; Claudio Favi; Federico Campi; Michele Germani. A Decision-Making Approach for Procuring Custom-Made Machineries and Components. 2021, 1 .
AMA StyleMarco Mandolini, Claudio Favi, Federico Campi, Michele Germani. A Decision-Making Approach for Procuring Custom-Made Machineries and Components. . 2021; ():1.
Chicago/Turabian StyleMarco Mandolini; Claudio Favi; Federico Campi; Michele Germani. 2021. "A Decision-Making Approach for Procuring Custom-Made Machineries and Components." , no. : 1.
The paper proposes a method to couple manufacturing knowledge in the context of casting with 3D CAD modelling and design. The approach allows formalizing tacit into explicit design knowledge, for aiding engineers during the development of metal casted components. It is based on three main pillars: (i) identification of geometrical features (3D CAD features) and parameters that can cause an issue during the manufacturing process, (ii) definition of a numerical threshold for feature parameters that guarantee the feasibility of the casting process, and (iii) representation of design rules within a CAD system to support product design review. The method is considered the starting point for future developing a software tool (CAD tool plug-in), here just presented. Two case studies are reported with the aim to show the advantages of the proposed method and tool in the identification of manufacturing issues early in the product development process. Results highlight how the CAD-based tool is a useful assistant to avoid design problems related to the metal casting process.
Claudio Favi; Marco Mandolini; Federico Campi; Michele Germani. A CAD-based design for manufacturing method for casted components. Procedia CIRP 2021, 100, 235 -240.
AMA StyleClaudio Favi, Marco Mandolini, Federico Campi, Michele Germani. A CAD-based design for manufacturing method for casted components. Procedia CIRP. 2021; 100 ():235-240.
Chicago/Turabian StyleClaudio Favi; Marco Mandolini; Federico Campi; Michele Germani. 2021. "A CAD-based design for manufacturing method for casted components." Procedia CIRP 100, no. : 235-240.
Face masks are currently considered key equipment to protect people against the COVID-19 pandemic. The demand for such devices is considerable, as is the amount of plastic waste generated after their use (approximately 1.6 million tons/day since the outbreak). Even if the sanitary emergency must have the maximum priority, environmental concerns require investigation to find possible mitigation solutions. The aim of this work is to develop an eco-design actions guide that supports the design of dedicated masks, in a manner to reduce the negative impacts of these devices on the environment during the pandemic period. Toward this aim, an environmental assessment based on life cycle assessment and circularity assessment (material circularity indicator) of different types of masks have been carried out on (i) a 3D-printed mask with changeable filters, (ii) a surgical mask, (iii) an FFP2 mask with valve, (iv) an FFP2 mask without valve, and (v) a washable mask. Results highlight how reusable masks (i.e., 3D-printed masks and washable masks) are the most sustainable from a life cycle perspective, drastically reducing the environmental impacts in all categories. The outcomes of the analysis provide a framework to derive a set of eco-design guidelines which have been used to design a new device that couples protection requirements against the virus and environmental sustainability.
Núria Boix Rodríguez; Giovanni Formentini; Claudio Favi; Marco Marconi. Engineering Design Process of Face Masks Based on Circularity and Life Cycle Assessment in the Constraint of the COVID-19 Pandemic. Sustainability 2021, 13, 4948 .
AMA StyleNúria Boix Rodríguez, Giovanni Formentini, Claudio Favi, Marco Marconi. Engineering Design Process of Face Masks Based on Circularity and Life Cycle Assessment in the Constraint of the COVID-19 Pandemic. Sustainability. 2021; 13 (9):4948.
Chicago/Turabian StyleNúria Boix Rodríguez; Giovanni Formentini; Claudio Favi; Marco Marconi. 2021. "Engineering Design Process of Face Masks Based on Circularity and Life Cycle Assessment in the Constraint of the COVID-19 Pandemic." Sustainability 13, no. 9: 4948.
The paper provides a method to acquire, process, and represent DfMA rules to help designers and engineers in the development of mechanical products compliant with manufacturing and assembly technology. This research work wants to define a general method able to link DfMA design guidelines (knowledge engineering) with geometrical product features that are available by the investigation of the 3D model. Numerical parameters of design features are related to design guidelines for the identification of manufacturing and assembly issues within the analysis of the 3D model.
Claudio Favi; Marco Mandolini; Federico Campi; Paolo Cicconi; Roberto Raffaeli; Michele Germani. Design for Manufacturing and Assembly: A Method for Rules Classification. Recent Advances in Computational Mechanics and Simulations 2021, 354 -359.
AMA StyleClaudio Favi, Marco Mandolini, Federico Campi, Paolo Cicconi, Roberto Raffaeli, Michele Germani. Design for Manufacturing and Assembly: A Method for Rules Classification. Recent Advances in Computational Mechanics and Simulations. 2021; ():354-359.
Chicago/Turabian StyleClaudio Favi; Marco Mandolini; Federico Campi; Paolo Cicconi; Roberto Raffaeli; Michele Germani. 2021. "Design for Manufacturing and Assembly: A Method for Rules Classification." Recent Advances in Computational Mechanics and Simulations , no. : 354-359.
The University of Parma is located in the north of Italy and it belongs to the oldest universities within the country. The size of this University is about 2,7000 students, with more than 5,000 graduates per year and 1,700 lecturers and administrative employees. Parma university has its sustainability report and has enlarged the focus about sustainability in its degrees. This chapter presents the results from the 116 survey respondents. The main focus of the university is on environmental issues, followed by cross-cutting themes, economic issues, and social ones. The contribution is high and the strength is low. The ranking of the competences shows that Inter-disciplinary work is the highest, followed by Critical thinking and analysis. The ranking of the pedagogical approaches resulted in Lecturing and Project- or Problem-based learning were the highest, followed by Case studies. The correlation analysis showed that Eco-justice and community, Community service learning, Jigsaw/Interlinked Teams, Participatory Action Research, and Case studies developed the most competences. The competences most developed were Personal involvement, Strategic action, and Assessment and evaluation. Based on the results some recommendations can be highlighted and implemented, such as the possibility to balance how sustainability concerns are tackle by different departments inside the university and to have a good balance of each issue inside sustainability dimensions, especially in the economic dimension. Traditional lecturing approach should leave space to learning-by doing and problem-based approaches which seems to be more compliant with the subject and the way to tackle sustainable concerns.
Claudio Favi. Sustainability Competences and Pedagogical Approaches at the University of Parma. Developing Sustainability Competences Through Pedagogical Approaches 2021, 63 -78.
AMA StyleClaudio Favi. Sustainability Competences and Pedagogical Approaches at the University of Parma. Developing Sustainability Competences Through Pedagogical Approaches. 2021; ():63-78.
Chicago/Turabian StyleClaudio Favi. 2021. "Sustainability Competences and Pedagogical Approaches at the University of Parma." Developing Sustainability Competences Through Pedagogical Approaches , no. : 63-78.
The use of engineering polymers for mechanical applications has seen increasing uptake due to properties such as low density, flexibility, ease of manufacturing and cost effectiveness. Despite these advantages, joining and assembly methods for these types of materials is still an open issue. Traditional assembly processes such as screw fastening and riveting are increasingly being replaced by new processes such as adhesive bonding. Engineering polymers, however, are difficult to bond using adhesives due to their low surface energy and low wettability. For this reason, surface chemical activation techniques with primers are often used. The utilization of various chemicals associated with such pre-treatments has a significant environmental impact. Within this context, the present paper aims to compare the environmental performance of four adhesive bonding pre-treatments: (i) mechanical (i.e., abrasion), (ii) chemical (i.e., primer), (iii) plasma and (iv) laser activation. The work was performed in three phases: (i) setup of the surface activation processes, (ii) mechanical characterization of bonded joints (static tests) and (iii) LCA analysis to evaluate and compare the different pre-treatments. The outcome of this study provides important insight into the development of laser and plasma technologies as sustainable surface activation methods for polymers through the creation of models correlating process parameters to the type of surface and joint strength.
Claudio Favi; Fabrizio Moroni; Adrian H.A. Lutey; Núria Boix Rodríguez. LCA of laser surface activation and traditional pre-treatments for adhesive bonding of engineering polymers. Procedia CIRP 2021, 98, 541 -546.
AMA StyleClaudio Favi, Fabrizio Moroni, Adrian H.A. Lutey, Núria Boix Rodríguez. LCA of laser surface activation and traditional pre-treatments for adhesive bonding of engineering polymers. Procedia CIRP. 2021; 98 ():541-546.
Chicago/Turabian StyleClaudio Favi; Fabrizio Moroni; Adrian H.A. Lutey; Núria Boix Rodríguez. 2021. "LCA of laser surface activation and traditional pre-treatments for adhesive bonding of engineering polymers." Procedia CIRP 98, no. : 541-546.
Welding is a consolidated technology used to manufacture/assemble large products and structures. Currently, welding design issues are tackled downstream of the 3D modeling, lacking concurrent development of design and manufacturing engineering activities. This study aims to define a method to formalize welding knowledge that can be reused as a base for the development of an engineering design platform, applying design for assembly method to assure product manufacturability and welding operations (design for welding (DFW)). The method of ontology (rule-based system) is used to translate tacit knowledge into explicit knowledge, while geometrical feature recognition with parametric modeling is adopted to couple geometrical information with the identification of welding issues. Results show how, within the design phase, manufacturing issues related to the welding operations can be identified and fixed. Two metal structures (a jack adapter of a heavy-duty prop and a lateral frame of a bracket structure) fabricated with arc welding processes were used as case studies and the following benefits were highlighted: (i) anticipation of welding issues related to the product geometry and (ii) reduction of effort and time required for the design review. In conclusion, this research moves forward toward the direction of concurrent engineering, closing the gap between design and manufacturing.
Claudio Favi; Roberto Garziera; Federico Campi. A Rule-Based System to Promote Design for Manufacturing and Assembly in the Development of Welded Structure: Method and Tool Proposition. Applied Sciences 2021, 11, 2326 .
AMA StyleClaudio Favi, Roberto Garziera, Federico Campi. A Rule-Based System to Promote Design for Manufacturing and Assembly in the Development of Welded Structure: Method and Tool Proposition. Applied Sciences. 2021; 11 (5):2326.
Chicago/Turabian StyleClaudio Favi; Roberto Garziera; Federico Campi. 2021. "A Rule-Based System to Promote Design for Manufacturing and Assembly in the Development of Welded Structure: Method and Tool Proposition." Applied Sciences 11, no. 5: 2326.
Paolo Cicconi; Marco Mandorli; Claudio Favi; Federico Campi; Michele Germani. Metal Additive Manufacturing for the Rapid Prototyping of Shaped Parts: A Case Study. Computer-Aided Design and Applications 2021, 18, 1 .
AMA StylePaolo Cicconi, Marco Mandorli, Claudio Favi, Federico Campi, Michele Germani. Metal Additive Manufacturing for the Rapid Prototyping of Shaped Parts: A Case Study. Computer-Aided Design and Applications. 2021; 18 (5):1.
Chicago/Turabian StylePaolo Cicconi; Marco Mandorli; Claudio Favi; Federico Campi; Michele Germani. 2021. "Metal Additive Manufacturing for the Rapid Prototyping of Shaped Parts: A Case Study." Computer-Aided Design and Applications 18, no. 5: 1.
The paper provides a method to integrate Design for Welding (DFW) method with CAD systems. The method is based on three main phases: (i) definition of DFW rules for the development of mechanical products, (ii) link of DFW rules with product geometrical features that are available by the investigation of the 3D model, and (iii) integration with CAD systems to support product design review. A method and a software tool are described including their features to help designers in the product development process. Case study aims to validate the proposed method in the identification of assembly issues early in the product development process. The CAD-based DFW tool is a useful assistant to avoid design problems related to the welding technology.
Claudio Favi; Federico Campi. CAD-based design for welding (DFW) method. International Journal on Interactive Design and Manufacturing (IJIDeM) 2020, 15, 95 -97.
AMA StyleClaudio Favi, Federico Campi. CAD-based design for welding (DFW) method. International Journal on Interactive Design and Manufacturing (IJIDeM). 2020; 15 (1):95-97.
Chicago/Turabian StyleClaudio Favi; Federico Campi. 2020. "CAD-based design for welding (DFW) method." International Journal on Interactive Design and Manufacturing (IJIDeM) 15, no. 1: 95-97.
Open-die forging is a manufacturing process commonly used for realising simple shaped components with high mechanical performances and limited capability in terms of production volume. To date, an analytical model for estimating the costs of components manufactured with this technology is still an open issue. The paper aims to define an analytical model for cost estimation of axisymmetric components manufactured by open-die forging technology. The model is grounded on the analysis of geometrical features available at the design stage providing a detailed cost breakdown in relation to all the process phases and the raw material. The model allows predicting product cost, linking geometrical features and cost items, to carry out design-to-cost actions oriented to the reduction of manufacturing cost. The model is mainly conceived for design engineers, cost engineers and buyers, respectively, for improving the product design, the manufacturing process and the supply chain. Cost model and related schemas for collecting equations and data are presented, including the approach for sizing the raw material and a set of rules for modelling the related cost. Finally, analytic equations for modelling the cost of the whole forging process (i.e. billet cutting, heating, pre-smoothing, smoothing, upsetting, max-shoulder cogging, necking and shoulders cogging) are reported. The cost model has been tested on eight cylindrical parts such as discs and shafts with different shapes, dimensions and materials. Two forge masters have been involved in the testing phase. The absolute average deviation between the actual and estimated costs is approximately 4% for raw material and 21% for the process. The absolute average deviation on the total cost (raw material and manufacturing process) is approximately 5%.
Federico Campi; Marco Mandolini; Claudio Favi; Emanuele Checcacci; Michele Germani. An analytical cost estimation model for the design of axisymmetric components with open-die forging technology. The International Journal of Advanced Manufacturing Technology 2020, 110, 1 -24.
AMA StyleFederico Campi, Marco Mandolini, Claudio Favi, Emanuele Checcacci, Michele Germani. An analytical cost estimation model for the design of axisymmetric components with open-die forging technology. The International Journal of Advanced Manufacturing Technology. 2020; 110 (7-8):1-24.
Chicago/Turabian StyleFederico Campi; Marco Mandolini; Claudio Favi; Emanuele Checcacci; Michele Germani. 2020. "An analytical cost estimation model for the design of axisymmetric components with open-die forging technology." The International Journal of Advanced Manufacturing Technology 110, no. 7-8: 1-24.
Design for disassembly is a key enabling strategy for the development of new business models based on the Industry 4.0 and circular economy paradigms. This paper attempts to define a method, based on Data Mining, for modelling disassembly data from large amount of records collected through the observation of de-manufacturing activities. The method allows to build a repository to characterize the disassembly time of joining elements (e.g. screws, nuts) considering different features and conditions. The approach was preliminary tested on a sample of 344 records for nuts disassembly retrieved by in-house tests. Disassembly time and corrective factors were assessed including the analysis of probability distribution function and standard deviation for each feature (i.e. disassembly tool).
Claudio Favi; Marco Marconi; Marco Mandolini; Michele Germani. Big data analysis for the estimation of disassembly time and de-manufacturing activity. Procedia CIRP 2020, 90, 617 -622.
AMA StyleClaudio Favi, Marco Marconi, Marco Mandolini, Michele Germani. Big data analysis for the estimation of disassembly time and de-manufacturing activity. Procedia CIRP. 2020; 90 ():617-622.
Chicago/Turabian StyleClaudio Favi; Marco Marconi; Marco Mandolini; Michele Germani. 2020. "Big data analysis for the estimation of disassembly time and de-manufacturing activity." Procedia CIRP 90, no. : 617-622.
Energy efficiency standards in the context of cooking appliances are an important strategy to preserve electric energy consumption and to reduce greenhouse gas emissions. Although successful standards and labels have been launched in many countries, the implementation of eco-design directive does have not a unique structure, energy policy and consumers understanding. The aim of this study is to describe the environmental performance of cooking appliances in real use conditions derived by the analysis of food habits and diets in EU countries. The final goal is to link cooking performance and the environmental features (i.e. energy consumptions, emissions) in different cooking conditions. The work is structured in three phases: (i) definition of recipes based on food habits in EU countries, (ii) development of energy consumption tests for each recipe, and (iii) characterization of eco-design actions considering the diet specificity. The outcome of this study provides interesting insights in the development of sustainable products for different markets as well as the definition of dedicated eco-design initiatives.
Claudio Favi; Giovanni Formentini; Núria Boix Rodríguez. Eco-design of cooking appliances based on food habits and diets. Procedia CIRP 2020, 90, 372 -376.
AMA StyleClaudio Favi, Giovanni Formentini, Núria Boix Rodríguez. Eco-design of cooking appliances based on food habits and diets. Procedia CIRP. 2020; 90 ():372-376.
Chicago/Turabian StyleClaudio Favi; Giovanni Formentini; Núria Boix Rodríguez. 2020. "Eco-design of cooking appliances based on food habits and diets." Procedia CIRP 90, no. : 372-376.
Internal insulation is a typical renovation solution in historic buildings with valuable façades. However, it entails moisture-related risks, which affect the durability and life-cycle environmental performance. In this context, the EU project RIBuild developed a risk assessment method for both hygrothermal and life-cycle performance of internal insulation, to support decision-making. This paper presents the stochastic Life Cycle Assessment method developed, which couples the LCA model to a Monte-Carlo simulation, providing results expressed by probability distributions. It is applied to five insulation solutions, considering different uncertain input parameters and building heating scenarios. In addition, the influence of data variability and quality on the result is analyzed, by using input data from two sources: distributions derived from a generic Life Cycle Inventory database and “deterministic” data from Environmental Product Declarations. The outcomes highlight remarkable differences between the two datasets that lead to substantial variations on the systems performance ranking at the production stage. Looking at the life-cycle impact, the general trend of the output distributions is quite similar among simulation groups and insulation systems. Hence, while a ranking of the solutions based on a “deterministic” approach provides misleading information, the stochastic approach provides more realistic results in the context of decision-making.
Elisa Di Giuseppe; Marco D’Orazio; Guangli Du; Claudio Favi; Sébastien Lasvaux; Gianluca Maracchini; Pierryves Padey. A Stochastic Approach to LCA of Internal Insulation Solutions for Historic Buildings. Sustainability 2020, 12, 1535 .
AMA StyleElisa Di Giuseppe, Marco D’Orazio, Guangli Du, Claudio Favi, Sébastien Lasvaux, Gianluca Maracchini, Pierryves Padey. A Stochastic Approach to LCA of Internal Insulation Solutions for Historic Buildings. Sustainability. 2020; 12 (4):1535.
Chicago/Turabian StyleElisa Di Giuseppe; Marco D’Orazio; Guangli Du; Claudio Favi; Sébastien Lasvaux; Gianluca Maracchini; Pierryves Padey. 2020. "A Stochastic Approach to LCA of Internal Insulation Solutions for Historic Buildings." Sustainability 12, no. 4: 1535.
Daniele Landi; Marta Rossi; Claudio Favi; Agnese Brunzini; Michaela Germani. A Virtual Design Approach to Simulate the Hob Energy Performance. Computer-Aided Design and Applications 2020, 17, 1 .
AMA StyleDaniele Landi, Marta Rossi, Claudio Favi, Agnese Brunzini, Michaela Germani. A Virtual Design Approach to Simulate the Hob Energy Performance. Computer-Aided Design and Applications. 2020; 17 (5):1.
Chicago/Turabian StyleDaniele Landi; Marta Rossi; Claudio Favi; Agnese Brunzini; Michaela Germani. 2020. "A Virtual Design Approach to Simulate the Hob Energy Performance." Computer-Aided Design and Applications 17, no. 5: 1.
Target pricing is a methodology to develop competitive products by determining the target price from market analyses. To guarantee the right profit margin, target cost is a direct consequence of target price. In this situation, the manufacturing cost estimation at the design phase becomes an essential task. The paper presents a framework for collecting knowledge required for estimating manufacturing cost of components. The framework consists of: (i) a cost breakdown structure used for splitting manufacturing costs, (ii) a data model for collecting that knowledge required for defining manufacturing processes, (iii) a data model for the collecting that knowledge required for computing the manufacturing cost of each operation within a manufacturing process and (iv) a workflow for analytically estimating cost of components. The framework has been mainly conceived for managing components realized through forming and shaping processes. The result presented in this paper guarantee the following benefits: (i) knowledge elicitation on product manufacturing cost, (ii) knowledge sharing among design/engineering departments, and (iii) knowledge capitalization for decision-making process.
Marco Mandolini; Claudio Favi; Federico Campi; Roberto Raffaeli. A Knowledge Formalization Approach for Manufacturing Cost Estimation. Recent Advances in Computational Mechanics and Simulations 2019, 279 -290.
AMA StyleMarco Mandolini, Claudio Favi, Federico Campi, Roberto Raffaeli. A Knowledge Formalization Approach for Manufacturing Cost Estimation. Recent Advances in Computational Mechanics and Simulations. 2019; ():279-290.
Chicago/Turabian StyleMarco Mandolini; Claudio Favi; Federico Campi; Roberto Raffaeli. 2019. "A Knowledge Formalization Approach for Manufacturing Cost Estimation." Recent Advances in Computational Mechanics and Simulations , no. : 279-290.
Conceptual design for assembly and installation is a key enabler for the improvement and development of an aircraft and related components. This work attempts to define a design for assembly methodology suitable for the evaluation and architecture design of aircraft systems in the preliminary phases of product development (conceptual design). Three main aspects are covered within this work: (i) the definition of a design framework, (ii) the characterization of suitable parameters driving the assessment and development of product architectures, and (iii) the formalization of internal knowledge for that purpose. The proposed approach has been tested in the assessment and development of an aircraft nose section with positive outcomes in terms of knowledge formalization and robustness of results in relation with the issues retrieved by the analysis of the assembly line. Future works will focus on the methodology optimization including automatic data input and mathematical models refinement.
Claudio Favi; Giovanni Formentini; Francois Bouissiere; Claude Cuiller; Pierre-Eric Dereux; Corentin Malchair. Design for Assembly in the Conceptual Development of Aircraft Systems. Recent Advances in Computational Mechanics and Simulations 2019, 268 -278.
AMA StyleClaudio Favi, Giovanni Formentini, Francois Bouissiere, Claude Cuiller, Pierre-Eric Dereux, Corentin Malchair. Design for Assembly in the Conceptual Development of Aircraft Systems. Recent Advances in Computational Mechanics and Simulations. 2019; ():268-278.
Chicago/Turabian StyleClaudio Favi; Giovanni Formentini; Francois Bouissiere; Claude Cuiller; Pierre-Eric Dereux; Corentin Malchair. 2019. "Design for Assembly in the Conceptual Development of Aircraft Systems." Recent Advances in Computational Mechanics and Simulations , no. : 268-278.
Welding is a widely used technology that allows the joining of thick metal plates for the development of large structures (e.g. piping, tanks, vessels). Many industries are intensively using welding for manufacturing and assembly activities. Sustainability assessment of welded structures is currently performed with misleading information in terms of data heterogeneity (nature) and quality (source). The data required to carry out a robust environmental analysis are spread among different documents and become available only when the project is finalized. This paper aims to define a data framework for a life cycle inventory of metal arc welding processes to preventively assess the environmental performances of different processes for comparison and decision-making analysis. The framework is presented as innovative solutions for life cycle inventory that provide (i) a common data structure (model), (ii) necessary data (input/output), and (iii) physical allocation/placement of data (project design documents). This study was performed in accordance with the international standard organization ISO 14040/14044 by using an attributional life cycle assessment (aLCA). Two structures (an oil and gas riser and a ship hull) were investigated considering the same functional unit: the manufacturing, use, and disposal of a welded structure able to guarantee the engineering requirements (according to a specific standard) in terms of strain, stress, and corrosion allowance over the expected lifetime of 20 years. In both cases, the share of welding process in respect to an overall product/structure life cycle impact assessment is strictly dependant on the project design choice and can be negligible for high-corrosion-resistance materials (e.g., Inconel alloy). On the other hand, the use of traditional metals (e.g., carbon steel) allows a large decrease of the environmental load, and the influence of the welding process becomes significant in a life cycle perspective.
Claudio Favi; Federico Campi; Michele Germani; Marco Mandolini. A data framework for environmental assessment of metal arc welding processes and welded structures during the design phase. The International Journal of Advanced Manufacturing Technology 2019, 105, 967 -993.
AMA StyleClaudio Favi, Federico Campi, Michele Germani, Marco Mandolini. A data framework for environmental assessment of metal arc welding processes and welded structures during the design phase. The International Journal of Advanced Manufacturing Technology. 2019; 105 (1-4):967-993.
Chicago/Turabian StyleClaudio Favi; Federico Campi; Michele Germani; Marco Mandolini. 2019. "A data framework for environmental assessment of metal arc welding processes and welded structures during the design phase." The International Journal of Advanced Manufacturing Technology 105, no. 1-4: 967-993.
Daniele Landi; Marta Rossi; Claudio Favi; Agnese Brunzini; Anna Costanza Russo; Michele Germani. A Virtual Design Approach to Simulate the Hob Energy Performance. Proceedings of CAD'19 2019, 1 .
AMA StyleDaniele Landi, Marta Rossi, Claudio Favi, Agnese Brunzini, Anna Costanza Russo, Michele Germani. A Virtual Design Approach to Simulate the Hob Energy Performance. Proceedings of CAD'19. 2019; ():1.
Chicago/Turabian StyleDaniele Landi; Marta Rossi; Claudio Favi; Agnese Brunzini; Anna Costanza Russo; Michele Germani. 2019. "A Virtual Design Approach to Simulate the Hob Energy Performance." Proceedings of CAD'19 , no. : 1.
The paper aims to analyze and compare the environmental performances of metal arc welding technologies: gas metal arc welding (GMAW), shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), submerged arc welding (SAW), and flux-cored arc welding (FCAW). Welding is considered one of the most energy-intensive processes in manufacturing. This study was performed in accordance with the international standard ISO 14040/14044 by using attributional life cycle assessment (aLCA). The functional unit is defined as the “the development of 1 metre of welding seam (qualified by ASME section IX requirements) to join 25 millimetres thick of metal plates made in carbon steel material and considering a V-bevel configuration.” Different configurations of base/filler materials and standardized bevel geometries have been analyzed as welding scenarios. The inventory considers all inputs (e.g., electric energy and filler material) and outputs (e.g., fume emissions and slags) involved in each welding process. A framework for data collection starting from available project documentation is presented as an innovative solution for the inventory phase. The impact assessment includes the human health, resources (midpoints/endpoint), and ecosystems (endpoint) categories from the ReCiPe (H) and cumulative energy demand (CED) methods. This study reveals a notable dominance in terms of the environmental burdens of GTAW and SMAW processes, as they present higher impacts in most of the impact categories. SMAW is the most energy-consuming process, and this aspect is reflected in the environmental performance. Conversely, GMAW presents the least environmental load, accounting for less than one third compared with GTAW in terms of the CED indicator and performing very well in terms of the ReCiPe endpoint indicator. Via analysis of different scenarios, the main outcomes are the following: (i) the use of V bevels significantly increases the environmental load when the metal plate thickness increases and (ii) the use of specific materials such as Inconel alloy exacerbates the environmental concerns associated with welding processes. The use of project documentation allows robust analysis of welding activity. Sensitivity analysis shows how the range of values for specific parameters (e.g., volts and amps) affects each technology in a different manner. Indeed, those ranges have a limited impact on the result accuracy (up to 20%) for more automatized welding processes (e.g., GMAW, SAW, and FCAW), in which only a small number of parameters are set by the operator, and the operator skills are less influential on the quality of the weld.
Claudio Favi; Federico Campi; Michele Germani. Comparative life cycle assessment of metal arc welding technologies by using engineering design documentation. The International Journal of Life Cycle Assessment 2019, 24, 2140 -2172.
AMA StyleClaudio Favi, Federico Campi, Michele Germani. Comparative life cycle assessment of metal arc welding technologies by using engineering design documentation. The International Journal of Life Cycle Assessment. 2019; 24 (12):2140-2172.
Chicago/Turabian StyleClaudio Favi; Federico Campi; Michele Germani. 2019. "Comparative life cycle assessment of metal arc welding technologies by using engineering design documentation." The International Journal of Life Cycle Assessment 24, no. 12: 2140-2172.