Research Project Summary Information
Energy Efficient Forming of Sheet Titanium Parts at Elevated Temperature (ST9663-1)
DynaBil Industries Inc
DynaBil Industries Inc. has partnered with the Center for Automation Technologies and Systems (CATS) at Rensselaer Polytechnic Institute for the specification of an energy efficient titanium hot forming process. The current process used by DynaBil to manufacture metal parts is very inefficient and creates a significant amount of waste heat. DynaBil proposes to conduct a systematic review to more completely understand the hot forming process to eventually design and develop an energy efficient automated hot forming process in the "hotsize" area. In this area, small- to medium-size, pre-cut, largely planar titanium blanks are formed into three-dimensional shapes using two-part, heated dyes in a single operation.
DynaBil plans to study the heat transfer mechanism at work in the hotsize operation so as to understand how to optimize it, and to investigate specific strategies for improving the throughput of the operation and, consequently, its energy efficiency.
The project is expected to reduce the energy consumption by 50%, which would be a projected annual savings of $18,000. Additionally, the proposed project will reduce peak load and utilize excess waste heat, along with producing several other environmental and economic benefits.
Dynabil installed a tooling pre-heat oven prior to the beginning of the project, therefore shifting the task away from an analysis aimed at justification to an analysis of the optimal temperature setting. It was determined that the maximum operating temperature is the optimal temperature, as the pre-heat oven is more efficient than the hotsize press. Also, it was determined that the greatest potential productivity improvement has been found to be in the reduction of the soak times that are currently used. A simple analysis demonstrates that parts reach equilibrium temperature much sooner than the soak times that are currently used would seem to indicate. If the soak times can be reduced as the modeling suggests, then significant throughput and energy savings should be achievable. For a few representative parts, the throughput improvement ranges from about 60% to about 140% and the energy savings per part ranges from about 2.5 to about 4 kW-h. Conversely, higher throughput will require that the press be opened more frequently, and at this time it is unclear if the press could keep up with the heat loss associated with more frequent opening.
DynaBil Industries Inc
PO BOX 810
Coxsackie, NY 12051
Rensselaer Polytechnic Institute
On-site Process Improvement
NYSERDA Contact Information
R&D - Mfg Tech & On-Site Pwr