Quality-conscious optimization of energy consumption in a grinding process applying sustainability indicators

The rising awareness of energy consumption and the environmental impact of manufacturing underline the need to implement structured approaches, such as a life cycle assessment, or metrics for process evaluation. Energy savings on their own are not sufficient to increase the process efficiency of industrial finishing operations, since the results, in terms of machined part quality, have to be accounted for. The research work presented in this paper applies sustainable development concepts to an industrial case study. A shaping grinding process (a flute grinding operation for tap manufacturing) has been assessed experimentally. The effects of variations in the process parameters have been discussed, with respect to processing time, energy consumption, and product quality/integrity. Whenever the optimization goals are in contrast, a trade-off between product requirements and process sustainability has to be introduced. In order to achieve energy savings, without altering the performance of the product, a specific efficiency sustainability indicator has been implemented and coupled to the life cycle inventory phase. The results provide a tool that can assist the decision-making stage and can be incorporated into a business strategy development framework.