At present, there are still many problems in China’s manufacturing industry, such as low-carbon manufacturing, energy saving, insufficient investment, low energy efficiency and so on. Among them, many industries have low energy efficiency and carbon emission benefits, especially in the foundry industry. At present, the research on the casting industry is mostly based on the production process of castings, and the relevant evaluation models are put forward from the aspects of production efficiency, economic benefits, carbon emissions and so on. However, there are few studies on energy saving and emission reduction aimed at the improvement of process design characteristics of casting products. Previous studies have ignored the benefit relationship between carbon emissions and time and cost. Considering the relationship between them, some scholars have put forward a comprehensive evaluation index of carbon benefit of turning tool parameter optimization, which can guide the process design of [60] design stage. However, this method is limited to a certain process, the actual production process will be more complex, when the process changes greatly, the carbon benefit can not be reflected. To the best of ZHY Cating’s knowledge, there is no carbon benefit assessment specific to the foundry industry. There are some similarities between casting and turning. Therefore, the evaluation of carbon benefit can also be used in the planning and design of casting process. However, a benefit evaluation method which can be evaluated with the continuous change of the process is needed to evaluate the benefits of the current foundry industry and the design method of the foundry process in the future.
Casting as an important producer of carbon emissions, good benefit evaluation and management is very important for energy saving and emission reduction, which can effectively help to improve the energy consumption of the foundry industry. Because of many energy sources, complex energy flow, great dynamic change and diverse influence, the research on carbon emission of manufacturing system is complex. How to evaluate, manage and ensure the improvement of carbon efficiency in the foundry industry is a great challenge. Therefore, there is an urgent need for innovative and practical evaluation methods. By studying the process design characteristics of casting, the relationship between process design features and carbon emission and resource consumption can be well established, the process parameters associated with the features can be optimized, and the quality of casting production can be improved. in order to obtain good benefits. At present, the index considered in the study is relatively single, which needs to meet different needs of the carbon benefit model. The research on energy saving and emission reduction of casting process design characteristics should solve the following problems.
The main contents are as follows:
(1) the classification of casting process design features and the analysis of their influence on resource consumption and carbon emission.
(2) the calculation and optimization method of casting-oriented process planning feature carbon benefit model can optimize the process parameters related to casting process planning characteristics and meet different process planning and multiple optimization objectives.
(3) the influence of the method of characteristic carbon benefit of process design on current and future process design.
The purpose of this paper is to take the process design characteristics that affect the product quality in the sand casting process design as the object. Based on the analysis and study of process planning characteristics, process planning features are classified, and a carbon benefit model based on process planning feature carbon emission, production time and resource cost model is established. Different process plans are established by studying different process design characteristics. Under the requirement of ensuring the quality of castings, taking the characteristic carbon benefit of process design as the optimization goal, the process parameters related to the characteristics of process design were optimized by using the optimization method. This method can optimize the process design scheme in the design stage and get the process plan that is most suitable for enterprise production in actual production. The research results provide the support of basic theories and specific methods for the benefit evaluation and process design characteristics of sand casting, and provide the research basis for the design of sustainable process plan for the follow-up sand casting industry. In the future research, the study of process design characteristics can be applied to more new casting processes and casting technologies. The contribution is to study the application effect of the process planning characteristic carbon benefit model in the manufacturing industry, and improve the resource level and efficiency of the traditional manufacturing industry by controlling the carbon emissions and resource utilization in the subsequent production process in the product design stage.
