MC 1 Brake Forming Process

Unit Process Life Cycle Inventory

Dr. Devi Kalla, Dr. Janet Twomey, and Dr. Michael Overcash
June 09, 2009
Brake ormin! "rocess #ummary.......................................................................................2
Methodolo!y o$ unit %rocess li$e cycle inventory model &u%lci'........................................(
Brake ormin! "rocess )ner!y *haracteristics...................................................................+
,. "arameters a$$ectin! the )ner!y re-uired $or .rake $ormin!........................................./
Brake ormin! )ner!y.....................................................................................................0
12die width selection, 3..............................................................................................0
12.end $orce calculation4.............................................................................................9
)d!e .endin! $orce calculation4..................................................................................9
5dle )ner!y.....................................................................................................................62
Basic )ner!y..................................................................................................................62
B. Method o$ -uanti$ication $or mass loss4........................................................................67
*ase #tudy on Brake $ormin! %rocess...............................................................................67
"roduct Details...............................................................................................................6(
"rocess "arameters........................................................................................................6(
Brake $ormin! %rocess...................................................................................................6(
Time, "ower and )ner!y calculations $or 12.end.........................................................6(
#ummary4...........................................................................................................................68
9e$erences *ited................................................................................................................68
,%%endices........................................................................................................................6/
Manu$acturers 9e$erence Data......................................................................................6/
6
Brake Forming Process Summary
Brake $ormin! is one o$ the mechanical metal de$ormation unit %rocesses in
manu$acturin! to %roduce sha%ed work%ieces. 5t is in the manu$acturin! unit %rocess
ta:onomy cate!ory o$ mass conservin! &M*' where.y the sha%e o$ the solid work%iece is
altered .y %lastic de$ormation while retainin! the same mass or com%osition. ;ence this
unit %rocess li$e cycle inventory &u%lci' is to esta.lish re%resentative estimates o$ the
ener!y and mass losses $rom the .rake $ormin! unit %rocess. The .rake $ormin! unit
%rocess li$e cycle inventory &u%lci' %ro$ile is $or a hi!h %roduction manu$acturin!
o%eration, de$ined as the use o$ %rocesses that !enerally have hi!h automation and are at
the medium to hi!h throu!h%ut %roduction com%ared to all other machines that %er$orm a
similar o%eration. This is consistent with the li$e cycle !oal o$ estimatin! ener!y use and
mass losses re%resentative o$ e$$icient %roduct manu$acturin!.
5n .rake $ormin! a sha%ed sheet metal is $ormed alon! a strai!ht a:is .y means o$
a <2sha%ed, 12sha%ed, or channel2sha%ed %unch and die set. , sheet metal work%iece is
%laced on a die and hori=ontally %ositioned a!ainst sto%s &.ack!ua!e'. , .end an!le is
%roduced .y a %unch, $orcin! the work%iece into the die. The metal on the inside %ortion
o$ the .end is com%ressed or shrunk, and the metal outside %ortion is stretched. >enerally
the material thickness ran!e can .e 0.0 mm ? 62.+ mm with len!ths o$ the metal sheet
alon! the .end o$ 6+ cm ? 60 m &Kal%ak@ian et al., 2000'. The len!th o$ the sheet is
limited .y the si=e o$ the %ress .rake. 5n this %rocess the work%iece is %laced over an
o%en die and %ressed down into the die .y a %unch that is actuated .y the ram %ortion o$ a
machine called %ress .rake. "ress .rakes are also used to $orm metals into com%le:
sha%es. ,n e:am%le com%uter numerical control &*A*' %ress .rake machine is !iven in
i!ure M*6.6, while the .rake $ormin! mechanism is illustrated in i!ure M*6.2. *A*
%ress .rakes are standard hydraulic %ress .rakes with a numerical control &A*' .ack
!ua!e $itted to the machine. Main advanta!e o$ *A* %ress .rake is the ca%a.ility to do
multi%le an!le %arts without any manual intervention with the .ack!ua!e or de%th
%enetration o$ the ram. 9educed setu% time and hi!her %roduction are the result. The
illustration in i!ure M*6.2 %rovides a two2dimensional look at a ty%ical %ress .rake
setu%. The le$t side o$ the illustration shows the %ress .rake in the o%en %osition and the
ri!ht side shows it in a closed %osition, and then the %ress .raked metal work%iece is
shown.

2
Figure MC1.1 *om%uter numerical control &*A*' %ress .rake machine &"hoto!ra%h
$rom ;ellerBs #on, 5nc, Tar=ana, *,, <#,.'
Figure MC1.2 "rocess #chematic &Todd et al., 699('
i!ure M*6.7 shows an overview o$ the develo%ed environmental2.ased $actors
$or .rake $ormin! %rocess. 3hen work%iece and tool set &%unch and die tools' are in%ut
to the %rocess, all activities related to %ress .rake *A* machine and .rake $ormin!
%rocess are estimated, and then the ener!y consum%tion o$ the %ress .rake, waste
!enerated .y the tool set, and the lu.ricant oil -uantity are calculated. Ci$e cycle
inventory &C*5' data are evaluated usin! the resource data. ;ere the resource data are the
%ress .rake machine s%eci$ications, lu.ricant oil s%eci$ication, die s%eci$ication and so
on. 3aste %roduced is the lu.ricant oil. The ste% o$ -uanti$ication aims at $indin! the
actual out%uts o$ .rake $ormin! o%eration, the ener!y consumed $or the whole %rocess,
the waste $luid &lu.ricant oil' incurred and the .endin! tool usa!e.
7
Figure MC1.3 C*5 data $or .rake $ormin! %rocess
Methodology of unit process life cycle inventory model uplci!
5n order to assess a manu$acturin! %rocess e$$iciently in terms o$ environmental
im%act, the conce%t o$ unit o%eration is a%%lied. The unit o%eration consists o$ the in%uts,
%rocess, and out%uts o$ an o%eration. )ach unit %rocess is convertin! materialDchemical
in%uts into a trans$ormed materialDchemical out%ut. The unit %rocess dia!ram o$ a .rake
$ormin! %rocess is shown i!ure M*6.(.
Figure MC1.4 5n%ut2Out%ut dia!ram o$ .rake $ormin! %rocess
The trans$ormation o$ in%ut to out%ut in this re%ort !enerates $ive lci characteristics,
a. 5n%ut materials
.. )ner!y re-uired
c. Cosses o$ materials
d. Ma@or varia.les relatin! in%uts to out%uts
e. >enerated characteristics o$ the out%ut %roduct that o$ten enters the ne:t unit %rocess.
WorkPiece
Tool set
Lubricant oil
Energy
Press Brake, Fixing, Lubricant Oil
Product which
is bent
Noise
Heat
Waste
Lubricant
Waste tool set
Brake forming
(
Press brake
Brake forming Process
Z

!
"nerg# $onsum%tion of
Press brake
&ool set
Lubricant oil
Product
Work%iece and tool set
L$' ()&)
"esource #ata
$nvironmental factors
Brake Forming Process $nergy Characteristics
5n %ress .rake $ormin!, the toolin! and setu% are relatively sim%le. Because hi!h
%roduction .rake $ormin! is a semi2continuous %rocess, the lci is .ased on a
re%resentative o%erational se-uence, in which
6' 3ork set2u% !enerally occurs once at the start o$ a .atch in %roduction. Be$ore any
toolin! is installed, the ram must .e locked in the Eshut hei!htF %osition. Once the
%ress is locked in a %osition where the ram can no lon!er close any ti!hter, the
toolin! can slide sa$ely into the %ress. #et2u% is made on the .rake $ormin!
machine as the $irst work %iece is introduced into the machine. The work %iece is
%ositioned, all drawin!s and instructions are consulted, and the resultin! %ro!ram
is loaded. The total set2u% time must then .e divided .y the si=e o$ the .atch in
order to o.tain the set2u% time %er .rake $ormed %art. The ener!y consumed
durin! this set2u% %eriod is divided .y all the %arts %rocessed in that .atch and is
assumed to .e ne!li!i.le and is discussed in the e:am%le .elow.
2' Durin! loadin!, the work%iece is $ed onto the die and sto%%ed .y the %reset
.ack!au!e. ,t each %unch %osition a .ack sto% is mounted on the rear o$ the .ed
in order $or the %art to .e %ositioned correctly with res%ect to the .endin! tool.
This is at the level o$ Basic ener!y and is la.eled Coadin!.
7' "unch movin! downwards to the metal sur$ace. &5dle )ner!y' &;andlin!'
(' ,ctual .endin! %rocess occurs, as the %ress .rake is cycled, and the work metal is
.ent to the desired an!le around the nose radius o$ the %unch. The distance .y
which the %unch enters the die determines .end an!le and is controlled .y a shut
hei!ht. The to the reset %osition o%erator activates the %ress .y %ressin! a $oot
%edal &Ti% )ner!y'
+' "unch movin! u%wards. &5dle )ner!y' &;andlin!'
8' 3ork%ieces are taken away or rearran!ed $or another .rake $ormin! to .e
ty%ically sent $orward to another manu$acturin! unit %rocess. &Basic )ner!y'
&<nloadin!'
The machine considered in this study is a hydraulic %ress .rake .ecause the
de!ree o$ control is !reater com%ared to other %ress .rakes. ;ydraulic machinery are
machines and tools which use $luid %ower to do work.
5n this re%resentative unit %rocess, the li$e cycle characteristics can .e determined
on a %er sin!le .end .asis or on an entire work%iece .asis, i$ here are multi%le .ends.
#ince this is a hi!h %roduction %rocess, the start u% &at the .e!innin! o$ a .atch or shi$t' is
deemed to .e small and not included. 5n this u%lci, there are three ty%ical %ower levels
that will .e used, i!ure M*6.+. )ach %ower level, kw, is the incremental %ower not the
a.solute total %ower. Thus i$ electrical measurements are made, the kw durin! the ti%
measurement must have the idle and .asic %ower &kw' values su.tracted to o.tain this ti%
%ower &kw'. *orres%ondin!ly, there are times within the .rake $ormin! se-uence durin!
which these three %ower levels are used, i!ure M*6.+. The overall time %er %iece is
re$erred to as cycle time and is !enerally consistent in a .atch.
+
Figure MC1.5. Determination o$ %ower characteristics and ener!y re-uirements o$ "ress
.rakes.
The ste%s 2', 7', +', and 8' are estimated as re%resentative manu$acturersB values
$or use in this unit %rocess lci and ener!y re-uired $or .endin! material .y .rake $ormin!,
ste% (', is measured usin! .reak $ormin! $orce values. ;i!h %roduction .rake $ormin!
involves multi%le su.2o%erations illustrated in Ta.le M*6.6. There are thus many
varia.les which have some in$luence on the overall ener!y o$ the .rake $ormin! unit
%rocess. The system .oundaries are set to include only the use %hase o$ the %ress .rake
machine, disre!ardin! in%ut material %roduction, machine %roduction, maintenance and
dis%osal o$ the machine. #tock decoilers, strai!hteners, $eeders, %art handlin!, and scra%
removal systems are known as %ress .rake au:iliary e-ui%ments. Moreover, the
$unctionin! o$ the manu$acturin! machines is isolated, disre!ardin! the in$luence o$ the
other elements o$ the manu$acturin! system, such as material handlin! systems, $eedin!
ro.ots, etc. Other consuma.les such as lu.ricants and coolants are included.
8
Idle $nergy
".rake $ormin!
"idle
".asic
t.asic
tidle
Basic $nergy
%ip $nergy
Spindle and Coolant
motor Startup
Po&er
%ime
t$ormin!
Table MC1.1
Machine <nits and its $unctions
The ener!y consum%tion o$ .rake $ormin! is calculated as $ollows.
)total G ".asic H &t.asic ' I "idle H &tidle' I ".rake$ormin! H &t.rake$ormin!' &6'
where %ower and time are illustrated in i!ure M*6.+.
'( Parameters affecting the $nergy re)uired for *rake forming
,n a%%ro:imate im%ortance o$ the many varia.les in determinin! the .rake $ormin!
ener!y re-uirements was used to rank %arameters $rom most im%ortant to lower
im%ortance as $ollows4
6. Thickness o$ the material
2. "ro%erties o$ the material
7. Cen!th o$ .end line
(. #%eed o$ the %unch
+. Bend sha%e &<, 1, channel, modi$ied channel'
8. #%rin!.ack or ener!y release &relation o$ rated h% to actual ener!y use'
/. .ottom $orce
0. !eometry
9. %roduction rate
60. $riction at the %unch, die, and work%iece inter$aces.
66. machine ener!y durin! stand.y and idlin!
rom this %arameter list, only the to% + were selected $or use in this unit %rocess li$e
cycle with the others havin! lower in$luence on ener!y. )ner!y re-uired $or the overall
.rake $ormin! %rocess is also hi!hly de%endent on the time taken $or idle and .asic
o%erations.
$nergy Consuming Units Functions %ype of $nergy
M6 ;ydraulic %um%6 &Main "um%
with continuous circulation' Move the %istons .asic
connected to the ram
M2 ;ydraulic %um%2 *lam% the dies
.asic

Drives ,:is Movement servo motors Move .ack!ua!e with idle
&%edal with instruments' res%ect to the ta.le
"* com%uterIcontrol %anel6
&screen etc' *ontrol "anel2 Machine o%eration .asic
/
Brake Forming $nergy
Brake $ormin! time &t$ormin!' and %ower &"$ormin!' must .e determined $or the .rake
$ormin! ener!y and it is calculated $rom the more im%ortant %arameters !iven a.ove.
Brake $ormin! time is used to calculate a %art o$ the ener!y $or this unit %rocess.
Figure MC1.6. #chematic o$ .endin! mechanics
Two !eneral ty%es o$ .endin! are used in modern %ress workin!. One is 12die
.endin!, which is used e:tensively in .rake die o%erations as well as in stam%in! die
o%erations. 5n 12.endin!, a distinction can .e made .etween two variations4 air .endin!
and .ottomin!, i!ure M*6./. The second ty%e is ed!e &wi%e' die .endin!, i!ure
M*6.9.
Figure MC1.7. 12.end ty%es
+,die &idth selection- .
12die o%enin!s were determined .y o%erator @ud!ment, usually a ran!e 8 to 62
times the material thickness, with ei!ht times .ein! the o%timum width &)ric, 2000'. 5$
the .end is not 90, .ut some an!le J, i!ure M*6./, then the de%th o$ the die is di$$erent
than i!ure M*6.0, however in this u%lci we will still use the o%timum DG0T. <sin! the
o%timum width o$ the die G 0T &hal$ width G (T', i!ure M*6.0, the de%th is !iven .y
D G (TDtan &JD2' &J K 600
o
, J K 0
o
'
0
or illustration, the de%ths $or several an!les are as $ollows
J G 80
o
D G 8.9T
J G 90
o
D G (T
J G 620
o
D G 2.7T
J G 6/9
o
D G 0.07+T
+,*end force calculation/
, ty%ical .end o%eration is shown in i!ure M*6.0. The v2die o%enin! width must .e at
least ei!ht times the thickness o$ the metal sheet $or 90 .ends &,#M 5nternational,
2008'. Because the 90 v2sha%ed dies are e-uilateral ri!ht trian!les, the die de%th is
determined to .e 3D2 or (T. Distance the %unch enters the die determines the .end an!le
and is controlled .y the shut hei!ht o$ the machine. #hut hei!ht is the vertical distance
measured $rom the ram nose to the .ed when the ram is $ully closed.
Time $or .endin! a 12.end, t$ormin! G DD1 &2'
The e-uation to determine .endin! $orce is &>eor!e et al., 2000'4
G # C T
2
KD 3 &7'
3here4 G $orce, &l.$'
# G <ltimate tensile stren!th, &%si'
C G Cen!th o$ the .end, &in'
T G stock thickness, &in'
3 G die o%enin! width, &in'
D G 12die o%enin! de%th, &in'
1 G "unch s%eed &inDsec' &Based on Machine s%eci$ication'
K G *onstant $or die o%enin! distance &6.77 $or a die o%enin! o$ 0T'
can .e o.tained in Aewtons .y multi%lyin! in l.
$
.y (.(0

Figure MC1.8. 12Bend
$dge *ending force calculation/
, ty%ical wi%in! o%eration is shown in i!ure M*6.9. The ed!e $orce e-uation is4
G K # C T
2
D 3 &('
Ty%ical tensile stren!ths &#' o$ some materials are !iven in Ta.le M*.6.2.
3here4
G $orce, &l.$'
# G <ltimate tensile stren!th, &%si'
CG Cen!th o$ the .end, &in'
9
r6 G %unch radius, &in'
r2 G die radius, &in'
T G stock thickness, &in'
3 G die o%enin! width, &in' &r6 I r2 I T'
K G *onstant $or die o%enin! distance &0.68/ $or lar!e die and clearances to 0.777 $or
shar% die radii and hi!h %lastic workin! stress'

Figure MC1.9. )d!e &3i%e'2Bend
<sin! the .endin! $orce calculated in the a.ove, we can estimate the ener!y
re-uired to %er$orm the o%eration .y usin! the $ollowin!4
). G D &+'
3here4 ). G )ner!y &kJD.end'
G .endin! $orce, &kA'
D G die closed de%th, &mm'
"ower re-uired $or .rake $ormin! " G H1 &8'
3here 1 G "unch s%eed &mmDsec'
60
Table MC1.2. Ty%ical tensile stren!ths o$ some materials &Tschatsch, 2008'
Material %ensile strength- Psi Mpa!
Soft 0ard
Cead 782+2+000 &2+2(0' 2
Tin +0002/2+0&(02+0' 2
,luminum &99.0L' 67,7+0&92' 2(8,+8(&6/00'
;i!h2tension aluminum
alloy Ty%e (
72,8(0&22+' 89,860&(00'
Duralumin 78,990&2++' 89,860&(00'
Minc 26,/++&6+0' 78,280&2+0'
*o%%er 76,607279,00+&26+22/+' (7,+662+0,06+&7002(00'
Brass &/0470' (/,6(0&72+' /8,0/0&+70'
Brass &804(0' +7,9+0&7/2' /6,080&(90'
"hos%hor .ron=e +0,06+2/2,+60&(002+00' /2,+602600,//0&+002/+0'
Bron=e +0,06+2/2,+60 &(002+00' /2,+602600,//0 &+002/+0'
Aickel silver +0,/8728+,288&7+02(+0' /2,+602606,+28 &++02/00'
*old rolled iron sheet (8,(622++,66+&7202700' 2
#teel, 0.6L* (8,(62&720' +0,06+&(00'
#teel, 0.2L* +0,06+&(00' /2,+60&+00'
#teel, 0.7L* 8+,288&(+0' 0/,027&800'
#teel, 0.(L* 06,226&+80' 60(,(2/&/20'
#teel, 0.8L* 60(,(2/&/20' 670,+7(&900'
#teel, 0.0L* 670,+7(&900' 6+9,+(2&6600'
#teel, 6.0L* 6(+,070&6000' 600,++0&6700'
#ilicon steel sheet /9,//0&++0' 92,2/+&8+0'
#tainless steel sheet 92,2/+2606,+28&8+02/00' 2
Aickel 87,0682/2,+60&((02+00' 02,8/2296,7/(&+/02870'
Table MC1.3. 9ecommended minimum .end radius $or commercial -uality steel sheet,
stri% and %late &>roover, 2007'
Material #o$t ;ard
,luminium alloys 0 8T
Brass, low leaded 0 2T
Ma!nesium +T 67T
#teels4 low *, low alloy and ;#C, 0.+T (T
,ustenitic stainless steels 0.+h 8T
Titanium 0./T 7T
Titanium alloys 2.8T (T
66
Idle $nergy
)ner!y2consumin! %eri%heral e-ui%ments included in idle %ower &"
idle
'

are
shown in Ta.le M*6.6. The idle %ower characteri=es the load case when there is relative
movement o$ the tool and the work2%iece without chan!in! the sha%e o$ the .ody &e.!.
a:is movement' 2 ;andlin!. or .rake $ormin!, the handlin! times are the air time o$
a%%roach and retraction a$ter $ormin!. The idle time &t
idle
' is the sum o$ the handlin! time
&t
handlin!
' and the .rake$ormin! time &calculated a.ove as t
$ormin!
, e-uation 2', see i!ure
M*6.+. or .rake $ormin! machines, the handlin! times are the air time o$ a%%roach and
retraction a$ter $ormin!. 3e can calculate the handlin! times and ener!y as $ollows.
5dle ener!y G Ntime
handlin!
I time
$ormin!
OH "
idle
&/'
Durin! the .rake $ormin! %rocess the %unch is considered to .e at an o$$set o$ at
least 8 times the thickness o$ work%iece. )very time while .rake $ormin! the %unch
comes down $rom a hei!ht o$ 8 times the thickness o$ the work%iece and a!ain retraces
.ack to an o$$set %osition a$ter com%letin! the %rocess. ,%%roach time is 8T divided the
a%%roach s%eed, which de%ends on machine s%eci$ication. 3hile the retraction time may
.e lon!er than the .rake $ormin! time, this is estimated as the sum o$ the a%%roach and
.rake $ormin! times and divided .y the return s%eed, which de%ends on the machine
s%eci$ication
Time $or handlin! is
,%%roach I retraction times G time
handlin!
&0'
time
handlin!
G &8T'D,%%roach s%eed I &8TID'Dreturn s%eed
The .rake $ormin! time was %reviously calculated, e-uation 2
timeidle G thandlin! I t$ormin! &9'
rom these calculations the idle ener!y $or a sin!le hole is
) &JouleD.end' G &t
a%%roach
I t
retraction
' I t
$ormin!
OH "
idle

&60'
The avera!e idle %ower "idle o$ automated *A* %ress .rake machines is .etween
6,200 and 6+,000 watt
H
. &H This in$ormation is $rom the *A* manu$acturin! com%anies,
see ,%%endi: 6'. ,%%ro:imately ;andlin! time will vary $rom 0.6 to 60 min.
Basic $nergy
The .asic ener!y o$ a %ress .rake is the demand under runnin! conditions in
Estand2.y modeF. )ner!y2consumin! %eri%heral e-ui%ments included in .asic ener!y are
M6, M2 and "* $rom Ta.le M*6.6. There is no relative movement .etween the tool and
the work2%iece, .ut all com%onents that accom%lish the readiness $or o%eration &e.!.
machine control unit &M*<', unloaded motors, servo motors, %um%s' are still runnin! at
no load %ower consum%tion. Most o$ the automated *A* %ress .rake machines are not
switched o$$ when not $ormin! and have a constant .asic %ower.
The avera!e .asic %ower ".asic o$ automated *A* %ress .rake machines is
.etween 000 and 0,000 watt
H
&H rom *A* %ress .rake manu$acturin! com%anies the
62
.asic %ower ran!es $rom 6D0
th
to 6D(
th
o$ the ma:imum machine %ower, &see
Manu$acturers 9e$erence Data in ,%%endi:'. The lar!est consumer is the hydraulic
%ower unit.
Ostwald, 6908 has shown that the time to load a .lank or %art into a %ress and
then remove the %art is %ro%ortional to the %erimeter o$ the rectan!le which surrounds the
%art. This time can .e !iven .y t
loadDunload
G 7.0 I 0.66 &C I 3' &seconds'
3here C, 3 G rectan!ular envelo%e len!th and width, cm.
rom i!ure M9 6.+, the .asic time is !iven .y
T
.asic
G t
loadDunload
I t
handlin!
I t
$ormin!
&66'
where t
handlin!
I t
$ormin!
G t
idle
as determined in e-uation 9.
3ith only the $ollowin! in$ormation the unit %rocess li$e cycle ener!y $or .rake $ormin!
can .e estimated.
6. material o$ %art .ein! .ent and Ta.le M*6.2
2. thickness o$ the material
7. len!th o$ the sheet alon! the .end line
(. an!le o$ the .end &see illustrations %a!e 9'
+. %unch s%eed, usin! re%resentative manu$acturersB values, see ,%%endi:
B( Method of )uantification for mass loss/
or ordinary %ress2.rake o%erations such as .endin! and sim%le $ormin!, coolant oil is
less commonly used. ;ydraulic %ress .rakes use $luid %ower to do work. 5n this machine,
hi!h %ressure li-uid called hydraulic $luid is transmitted throu!hout the machine to
various hydraulic motors and hydraulic cylinders. 5n addition to trans$errin! ener!y,
hydraulic $luid needs to lu.ricate com%onents, sus%end contaminants and metal $ilin!s $or
trans%ort to the $ilter, and to $unction well to several hundred de!rees ahrenheit.
;ydraulic $luid re%lacement occurs so in$re-uently that on %er .end or %er 6,000 .end
.asis, this mass loss is ne!lected.
Cu.ricant oil is commonly &.ut not always' used on the metal sur$ace in contact
with the die. Cu.ricant is a%%lied alon! the .end line and then is some su.se-uent
%rocessin! ste%, it is removed .e$ore a $inal %roduct is used. 5n order to link this mass
loss directly to .rake $ormin!, it is included here. Aote the ener!y or ancillary waste $or
lu.ricant removal &solvent de!reasin!, ra! wi%e, etc' would .e ca%tured in the u%lci o$
those %rocesses and only the lu.ricant mass is assi!ned to .rake $ormin!. Cu.ricant
a%%lied and removed is estimated &Madavan, 3ichita #tate <niversity, 2009, %ersonal
communication' as +cm width : C &cm' : &2.+(D6000' cm thickness : 0.9 !Dcm
7
G 0.66
!Dcm len!th o$ .end.
Case Study on Brake forming process
5n this re%ort we analy=e the detailed ener!y consum%tion calculations in .rake
$ormin! %rocess. The $ormin! %rocess is %er$ormed on B,5C)5>; *A* %ress .rake
machine &B" ? +080'. The machine s%eci$ications are listed .elow4
67
Table MC 1.4. Machine s%eci$ication
#%eci$ications B'IL$I10
Model Aum.er BP,2343
Ma:. Bendin! $orce, kA +00
,%%roach #%eed, inDsec 7.6+
Bendin! #%eed, inDsec 0.20
9eturn #%eed, inDsec 2.(
Main motor, k3 7./
Motor 2, k3 0.(
7 ,:es motor
out%ut&P,Q,M', k3
0./+
Total Ma:imum "ower
consum%tion
8k3
Product #etails
or this e:am%le we are assumin! a stainless steel &so$t' sheet as the work %iece.
The work %iece is o$ sheet2metal %art o$ 7mm thick and 20mm .end len!th is .ent to an
included an!le o$ J G 620
0
and a .end radius o$ /.+ mm in a 12die. The o.@ective o$ the
study is to analy=e the ener!y consum%tion in %ress .rake machine. The die o%enin! is 2(
mm. The metal has tensile stren!th o$ 8/+ M%a.
Process Parameters
The $ormin! conditions and the %rocess %arameters are listed in Ta.le M*6.+.
Table MC1.5. "rocess "arameters $or ):am%le *ase
"rocess *onditions
#heet thickness &T' 0.62 in
<ltimate Tensile stren!th &<T#' 98,900 %si
Die o%enin! &3' 0.9( in
Bend an!le &,' 620 de!
Bend radius &9' 0.70 in
Bend Cen!th &C' 0./9 in
Die closed de%th, D 0.2/ in
Brake forming process
Durin! $ormin! o%eration the tool is considered to .e at an o$$set o$ 60mm &8
times the work%iece thickness' a.ove the work%iece. Durin! .rake $ormin! the tool
comes down $rom a hei!ht o$ 60mm. 5t retracts &DI60' mm .ack to the o$$set %osition
a$ter com%letin! the $ormin! %rocess.
%ime- Po&er and $nergy calculations for +,*end
The total %rocessin! time can .e divided into the 7 su. !rou%s o$ .asic, idle, and
.rake $ormin! time.
6(
Brake forming time/
The time $or .endin! is determined .y
t$ormin! G &D'D1 &sec'
3here 1 is the .endin! s%eed in mmDsec, and D is the die de%th in mm.
D G de%th o$ close die G 0.20 in &0.62H2.7, see %a!e 9'
1 G 0.20 inDsec
Time to .end will .e,
t$ormin! G &0.20 in'D0.20 inDsec'
G 6 secD.end
)ner!y re-uired $or each .end,
) G D H
The $orce re-uired to .end a 202mm lon! sheet o$ so$t stainless steel 7mm thick can .e
estimated usin! the $ollowin! calculation4
G # C T
2
KD 3
G 98,900 %si H &0./9' H &0.62'
2
H 6.77 G 6,+80 l.$ G /,000 A
0.9(
Brake $ormin! ener!y $or each .end,
) G /,000 A H 0.0089 m G 0.0(0 kJ
"ower re-uired " G H 1
G /,000 H 0.00/ G 0.0.0(9 k3D.end
0andling %ime/
The air time $or .endin! is a%%roach and retract time
,%%roach time G 60D00 G 0.22+ sec
9etracts time G &60 I D' D80 G 2(.9D80 G 0.(6+ sec
Total air time G 0.8( sec
Total idle time G t.$ I tair
G 6 I 0.8( G 6.8( sec
5dle %ower $rom ,%%endi: 6 can .e assumed as G 2.+ k3
5dle ener!y G 2.+ H 6.8( G (.62+ kJD.end
Basic time/
Coadin! and unloadin! time t G 7.0 I 0.66 &C I 3'
G 7.0 I 0.66 &2 I +'
G (.+/ sec G tlDu
".asic G 6.2+ k3
).asic G ".asic H t.asic
T.asic G tlDu I tidle G (.+/ I 6.8( G 8.2 sec
).asic G 6.2+ H 8.2 G /.0 kJD.end
%otal $nergy
)total G 0.20/ I (.62+ I /.0 G 62 kJD.end
Mass Loss
6+
Cu.ricant loss is 0.066 !Dcm len!th H2 cm len!th G 0.022 ! lu.ricant lossD.end
Summary/
This re%ort %resented the models, a%%roaches, and measures used to re%resent the unit
%rocess li$e cycle inventory &u%lci' o$ .rake $ormin! o%erations. The only ma@or
environmental characteristics are is the ener!y consum%tion o$ the %ress .rake and
lu.ricant loss. *alculations $or %roduct manu$acturin! are %resented, .ased on knowin!
only the .end len!th and the material .ent. The li$e cycle o$ .rake $ormin! is .ased on a
ty%ical hi!h %roduction scenario &on a *A* %ress .rake machine' to re$lect industrial
manu$acturin! %ractices.
The ener!y can .e calculated $rom a .asic list o$ varia.les, likely to .e known $or each
%art to .e .rake $ormed
6. material o$ %art .ein! .ent and Ta.le M*6.2
2. thickness o$ the material
7. len!th o$ the sheet alon! the .end line
(. an!le o$ the .end, illustrated on %a!e 9
+. %unch s%eed, usin! re%resentative manu$acturersB values
"eferences Cited
6. ,.ele, ).R ,nderl, 9.R and Birkho$er, ;. &200+' Environmentally-friendly product
development, #%rin!er21erla! Condon Cimited.
2. ,#M 5nternational. &2008' Metalworking: Sheet Forming Hand book, 1ol. 6(B,
,merican #ociety o$ material.
7. *larens, ,.R Mimmerman, J.R Keoleian, >.R and #kerlos, #. &2000' *om%arison o$
Ci$e *ycle )missions and )ner!y *onsum%tion $or )nvironmentally ada%ted
Metalworkin! luid #ystems, Environmental Science Technology,
60.6026Des000/96=.
(. )rik O.er!. &2000' Machinery! Handbook, 28
th
)dition, 5ndustrial "ress.
+. >eor!e, .#R and ,hmad, K. ). &2000' Manufacturing "roce!!e! # Material!, (
th
)dition, #ociety o$ Manu$acturin! )n!ineers.
8. >roover, M.". &2007' Fundamental! of Modern Manufacturing, "rentice ;all.
/. Kal%ak@ian, #.R and #chmid, #. &2000' Manufacturing "roce!!e! for Engineering
Material!, +
th
)dition, "rentice ;all.
0. Ostwald, ". &6996' Engineering co!t e!timating, 7
rd
)dition, "rentice ;all.
9. "iacitelli, 3.R #ie.er, et. al. &2000' Metalworkin! $luid e:%osures in small
machine sho%s4 an overview, ,5;,J, 8247+827/0.
60. #chuler >m.;. &6990' Metal forming Handbook, 6
st
)dition, #%rin!er.
66. Todd, 9.R ,llen, D.R and ,ltin!, C. &699(' Manufacturing proce!!e! reference
guide, 5ndustrial "ress, Aew Qork.
62. Tschatsch, ;ein=. &2008' Metal forming practice: "roce!!e!-machine!-tool!,
#%rin!er.
67. 3laschit=, ". and 3. ;o$lin!er. &200/' , new measurin! method to detect the
emissions o$ metal workin! $luid mist, $ournal for Ha%ardou! Material!,
6((4/782/(6.
68
'ppendices
Manufacturers "eference #ata
The methodolo!y that has .een $ollowed $or collectin! technical in$ormation
on *A* machines has .een lar!ely .ased in the $ollowin!4
The documentation o$ the *A* %ress .rake and the technical assistance
collected $rom the manu$acturin! com%anies throu!h the internet. #everal interviews
with the service %ersonnel o$ the di$$erent *A* manu$acturin! com%anies have .een
carried out. ,$ter collectin! the in$ormation $rom the di$$erent com%anies it has .een
%ut to!ether in the relevant document that descri.es the di$$erent a%%roaches the
di$$erent com%anies have re!ardin! the technical in$ormation on the *A* %ress .rake
machine. Tele%hone conversations allowed us to learn more a.out .asic %ower and
idle %ower. *om%anies that involved in our tele%hone conversations are Bailei!h,
9onmack, Trum%$ and *incinnati. These com%anies manu$acture di$$erent si=es o$
*A* machines, .ut this re%ort shows the lower, mid and hi!hest level o$ si=es. or
our case study we %icked machine at the mid level.
#%eci$ications B'IL$I10
Model Aum.er BP,5543 BP,2343 BP,6378
Bendin! $orce, kA 770 +00 900
,%%roach #%eed,
mmDsec
00 00 00
Bendin! #%eed, mmDsec / / /
9eturn #%eed, mmDsec 80 80 80
Main motor, k3 2.2 7./ /.(
Motor 2, k3 0.( 0.( 0.(
7 ,:es motor
out%ut&P,Q,M', k3
0./+ 0./+ 0./+
#%eci$ications "9:M'C;
Model Aum.er "M,<323 "M,5133 "M,8333
Bendin! $orce, kA 800 6+00 +000
,%%roach #%eed,
mmDsec
620 620 620
Bendin! #%eed, mmDsec 9 9 9
9eturn #%eed, mmDsec 600 00 00
Main motor, k3 +.+ 66 7/
Motor 2, k3 6 6 6
7 ,:es motor
out%ut&P,Q,M', k3
6 6 6
6/
#%eci$ications %"UMPF
Model Aum.er %B +,23 %B +,153 %B +,5<3
Bendin! $orce, kA +80 6((0 7+/0
,%%roach #%eed,
mmDsec
6+0 6+0 6+0
Bendin! #%eed, mmDsec 62 62 62
9eturn #%eed, mmDsec 620 620 620
Main motor, k3 8 60 7+
Motor 2, k3 6 6 6
7 ,:es motor
out%ut&P,Q,M', k3
6 6 6
#%eci$ications CI:CI::'%I
Model Aum.er 63M=4 172M=13 523M=1<
Bendin! $orce, kA +00 6200 (000
,%%roach #%eed,
mmDsec
700 2/+ 2+0
Bendin! #%eed, mmDsec 70 2+ 20
9eturn #%eed, mmDsec 200 600 6+0
Main motor, k3 6+ 20 2+
Motor 2, k3 2 2 2
7 ,:es motor
out%ut&P,Q,M', k3
6 6 6
60