´EnviroMan´ Environmentally adapted metal manufacturing processes; chemical and waste material recyc

Project time: 2012 – 2015

Budget: 20 660 000 SEK

Funding: FFI – Strategic Vehicle Research and Innovation

A study “before and after” EnviroMan, indicates that the project has created increased understanding on specific topics and also useful results

The project EnviroMan, Environmentally adapted metal manufacturing processes, is part of the FFI Strategic Vehicle Research and Innovation collaboration program Sustainable Production, handled by VINNOVA. Within this program, the project EnviroMan is part of the Swedish Manufacturing R&D Clusters roadmap, area Component Manufacturing. The EnviroMan project lasted from Oct 2012 to Aug 2015, performed by 23 partners from industry and research. The project is followed by a technology transfer initiative.
The R&D work had a wide scope, covering innovative and sustainable process fluid cleaning methods, environmentally adapted heat treatment processes, minimized waste products from foundries, and a specific focus on methods for energy and environmental analyses. A summary from the studies and the results from them are:
Innovative and sustainable cleaning of process fluids. Industrial case studies are specifically made on sustainable cleaning of process fluids from bacteria, in one case by the use of ozon at SKF, and in another by the use of UV light at Volvo CE. The results prove, that both methods give effect, but needs to be optimized according to process control, system design and handling routines. The UV light system needs weekly cleaning of the lamps, high quality of both the process fluid circulation and the process water. The ozon system was used in a process fluid system supporting 7 machines. Ozone is very efficient against bacteria, in this case the (maybe too) large fluid system needed a mix of both biocide and ozon treatment, to deliver good results during the evaluation. The overall goal: Reduce or eliminate the use of chemicals related to heat treatment ope-rations. Two specific areas have been studied: Cleaning of surfaces and quenching for re-duced environmental impact. The cleaning studies have evaluated different process fluids applied on steel surfaces, which were heat treated and analyzed by advanced methods. The effects of different cleaning operations prior to heat treatment were analysed. A con-clusion is, that it seems to be possible to extend the service-life of those washing/cleaning baths. The study according to polymer quenchants resulted in a guide, on how to handle quenchants in workshops. A prestudy using UV light treatment of polymer quenchants were made, as an alternative to biocides. This study needs to be followed by more R&D.
The major long term focus is to reduce or eliminate waste to landfill, but also to increase internal reuse of sand and fine-grained particles in foundries. Recirculation of bentonite sand generates fine-grained residuals, which has a potential to be used in a number of applications: Added to landfill sand. Landfill sand having 20% fine-grained residuals will result in a leakage-proof combination. Added to foundry sand: Fine-grained residuals can be added into foundry sand from about 20% to 50%, which means a robust and easy to control process. Life cycle analyses are made for different use of the sand.

Participating researcher(s)

Partners

Share

Similar projects

Streamlined Modeling and Decision Support for Fact-based Production Development (StreaMod)

The integration of data management systems, simulation software and optimization algorithms have been shown to increase throughput in existing production but also allow expanded use of virtual tools in the preparation phases. This in turn leads to shorter development times for new production systems and products. The project has also contributed to greater understanding and concrete improvements in the processes of collecting and assure the quality of production data. This in turn increases the quality in both simulations and direct data-driven analyzes.

2013 – 2017

Sintered parts with high static loading capacity

The project has confirmed the hypothesis that tailoring of the tempering is a functioning means of making PM steel sustainable towards high static loading in potential automotive applications. The project has also developed further understanding about mechanisms that could be responsible for static loading sensitivity with respect to creep/relaxation at slightly elevated temperature. The results relate to sustainable manufacturing processes, the basis being that powder compaction and sintering is an energy efficient way with high raw materials utilization.

2012 – 2013

Automotive components from renewable resources with good barrier properties and tailored biodegradability, for interior applications

Our hypothesis is that advanced, lightweight, multi-layer-structured composites with good barrier properties and tailored biodegradability can be produced by combining bio-based thermoplastic with special additives and pulp fiber mats. This material is free from fossil raw materials, sustainable, fire and impact-resistant and suitable for interior components in vehicles.

2012 – 2013

Virtual PaintShop – Simulation of Oven Curing

The paintshop is often a bottleneck in production and the processes are fine-tuned based on testing on numerous prototypes. To meet the future demands there is a great need to improve the product preparation process. The aim is to develop methods, techniques and software, and supporting measurement methodology, for simulation of paint curing in IR and convective ovens. The goal is to assist the industry to further develop and optimize their surface treatment to be more energy and cost efficient; to have a shorter lead time in product development; and to give a higher product quality.

2016 – 2019

Virtual PaintShop – Simulation of Oven Curing

Sustainable Manufacture of Future Engine Components

The project has addressed challenges in casting and realisation of new cast irons with improved properties and machinability, decision making regarding manufacturing strategies and machinability of materials. Silicon-alloyed compacted graphite iron (CGI) has been demonstrated av new alternative for future engine components. New simulation technique for assessing manufacturing strategies has been introduced. Generic know ledge has been developed w hen it concerns w ork material machinability w ith specific reference to combined materials in advanced components.

2012 – 2015

Dense-Arc joining of hybrid thermoplastic composite-metal structures (DENSARC)

The aim with the project is to test a new method to join thermoplastic composite to metal in a lap joint by using a focused TIG arc, as a heat source, to heat the metal side just enough so that the composite melts and join to the metal. The method gives single sided access, no need for additional filler material and makes invisible joints possible. The objective is to have a joining method that is robust, gives high productivity and high quality as well as cost advantages.

2012 – 2013

Compact and energy efficient transmissions – control and prediction of functional surface behavior

The overall objective of the project was to: • Develop simulation methodology for drive simulation of transmissions with given shape, surface topography and surface structure, - for more robust and better prediction of the efficiency and life of gear contacts in gearboxes. • Through experimental evaluation and characterization, support and verify the developed simulation technology • Through experimental evaluation and characterization, further verifying the potential of using the correct surface texture, e.g. honing, and right-handed gear in heavy-duty transmissions.

2016 – 2018

PADOK – Study Visit to India 2016

With globalization and other megatrends as demographic changes and climate change, more knowledge is needed regarding production in an international perspective. PADOK Study Visit in India 2016 have given an increased knowledge regarding how production is conducted in India, some of the challenges producing companies in that region is facing and how Swedish companies interested in investing in production in India could act to establish themselves in the region.

2016 – 2016

Geometry optimized adhesive joining for sustainable production

"Geometry Optimised adhesive joining for sustainable production” in Swedish (Geometri Optimerad LimFogning för hållbar produktion, "GOLF") is a project within the Swedish research program FFI for Sustainable production. It has as its mission to develop technology and methods to get the right amount of adhesive on the right place. The drivers behind this are the overall strive to decrease weight in vehicles and moving machines to minimize the amount of CO2 in the atmosphere.

2013 – 2015

Emerging digital technologies and their applicability as picking support in materials handling

In material handling processes, such as kitting and sequencing, which are used in the automotive industry to supply the assembly with a wide and growing range of component variants, the picking information system is central design aspect. Given the developments in digitization, the purpose of this concept study is to evaluate the potential of digital technology to support materials handling work in production systems.

2017 – 2017

Search Next Previous Deselect Project manager URL Document Partner Calendar Place Close Menu Expand User Log out Profile