Calculation of carbon emissions in metal forming manufacturing processes with eco-benign lubrication

This paper optimizes a common metal forming process (upset forming) with respect to: 1) the process; 2) reduction of CO2 emissions; 3) environmentally benign lubricants (palm oil ester and used cooking oil ester). The emphasis is on optimization of these three parameters, with respect to minimizing CO2 emissions, which is not commonly done in manufacturing. It is shown a 13.5% reduction in CO2 emissions can be achieved. The work includes experimental determination of Coulomb coefficients of friction using the ring test with environmentally benign lubricants. A simple FE model of upset forming is used to illustrate the optimization process. A clear and effective optimization method, which can be used as an auxiliary decision tool for a manufacturer in the metal forming sector in decreasing CO2 emissions is hereby presented.