More than 60% of household energy consumption in Ontario is for heating. Home heating needs in Ontario are driven by exterior temperatures that fluctuate throughout the day. Ontario’s electricity is generated from a different mix of primary energy sources from hour to hour. Using average hourly data for the electricity generation mix and hourly outside temperature data for each month of the year, we estimate residential heating loads and the electricity demands due to the use of three models of heat pump. Then we calculate the resultant greenhouse gas emissions and compare them to emissions if heat pumps are not used. We determine heating needs of single detached dwellings using prototypical average Ontario homes and building simulation software. Using heat pumps in all of these dwellings can reduce heating-related greenhouse gas emissions between 15% and 85% during January, the harshest month of the year. Using heat pumps could also reduce energy consumption for heating by between 12% and 68%, while requiring an approximate 5–25% increase in electricity demand. Heat pumps can provide a significant portion of home heat needs whilst reducing energy consumption and greenhouse gas emissions. Operating costs are lower than that of electric and oil heating, but similar to natural gas heating.

Home heating accounts for most of the residential energy use in Canada. While natural gas, oil-fired furnaces, and electric resistance are the dominant heating system choices, heat pumps have become a viable alternative. Heat pumps with lower minimum operating temperatures and better performance are increasing both their effectiveness and their number of hours of useful service. In this study, we apply System Dynamics to analyze the effects of technological development on the rate at which homeowners adopt residential air source heat pumps. We test the effects of low, moderate and high rates of technological development, as well as reduced electricity and carbon pricing on the predicted rate of adoption in Ontario. From the perspective of the use stage in life cycle assessment, we estimate energy savings and greenhouse gas emission reductions. We predict that using heat pumps will substantially reduce overall energy consumption, and in Ontario, where electricity is generated with little use of fossil fuels, it will also reduce greenhouse gas emissions.

Incremental sheet metal forming in general and Single Point Incremental Forming (SPIF) specifically have gone through a period of intensive development with growing attention from research institutes worldwide. The result of these efforts is significant progress in the understanding of the underlying forming mechanisms and opportunities as well as limitations associated with this category of flexible forming processes. Furthermore, creative process design efforts have enhanced the process capabilities and process planning methods. Also, simulation capabilities have evolved substantially. This review paper aims to provide an overview of the body of knowledge with respect to Single Point Incremental Forming. Without claiming to be exhaustive, each section aims for an up-to-date state-of-the-art review with corresponding conclusions on scientific progress and outlook on expected further developments.

A Donnan Dialysis based process utilizing cation exchange membranes to separate and recover lithium, nickel, cobalt, and manganese during hydrometallurgical recycling of lithium ion battery cathodes is proposed. Compared to conventional processes, the process has the potential to achieve higher lithium recoveries and to recycle lixiviant. The present work introduces the process, develops mathematical equations to describe it, presents experimentally found cation mass transfer coefficients through cation exchange membranes, and uses the experimental data and equations to predict theoretical kinetics and recoveries achievable by the process. The simulation predicts that in two days, utilizing 5000 dm(2) of CMS C-1805 Neosepta monovalent CEM and 2000 dm(2) of CMX C-1586 Neosepta polyvalent CEM, the proposed process is capable of processing 1000 L of leachate containing 285 mol of lithium, 95 mol each of cobalt, nickel, and manganese. 94.1% of the lithium can be recovered as high purity lithium carbonate and 99.4% of the transition metals as mixed sulphates ready for solvent extraction. At a minimum 422.6 mol of pure sulphuric acid and 268 mol of potassium bicarbonate are needed.

This chapter contains sections titled: Introduction Surface Treatment Techniques Coating Operations Tribology Evolving Technologies Micro Manufacturing Conclusions

Traditional quality control of resistance spot welds by analysis of the dynamic resistance signature (DRS) relies on manual feature selection to reduce the dimensionality prior to analysis. Manually selected features of the DRS may contain information that is not directly correlated to strength, reducing the accuracy of any classification performed. In this paper, correlations between the DRS and weld strength are automatically detected by calculating correlation coefficients between weld strength and principal components of the DRS. The key features of the DRS that correlate to weld strength are identified in a systematic manner. Systematically identifying relevant features of the DRS is useful as the correlations between weld strength and DRS may vary with process parameters.

This paper proposes how to evaluate environmental impacts in a product Life Cycle Assessment at the premanufacture (mining) stage using Toward Sustainable Mining principles. The material supply chain includes a choice between either recycling or mining where mining remains the primary supplier of materials for manufactured products. Integration of TSM with Streamlined life cycle assessment as the bases for an ISO standard on mining environmental impacts.

The forming tool in single point incremental forming (SPIF) follows a path prescribed by CAM software. As the tool follows this path, thereby deforming the sheet, both friction and deformation occur generating heat. The effect of increasing feed rates and tool rotation speed on resulting temperatures has been studied for AA 5754-H32. A flat tool was used to form a variable wall angle geometry and the temperatures were recorded using an infrared camera. The infrared camera was able to give a temperature gradient at the tool-sheet interface. It was found that along with geometry, lubricant and rig design also have an impact on the net heat within the system. In addition, beyond a certain limit, the high relative velocity can cause wear at the tool-sheet metal interface. The observations on temperature distribution are new and novel.

Abstract This article describes friction force as a function of normal force in dry forming. It focuses on metal forming operations usually classified as cold working and hot working based on metallurgical considerations. The article discusses surface flattening and roughening of workpiece asperities in metal forming. It presents advanced tribology models and results for friction in isothermal forging operations in which the tooling is maintained at a temperature close to that of the workpiece. The article provides information on heat transfer models. It discusses the effect of wear in manufacturing processes. The article concludes with information on the main categories of tool and die materials used for a variety of manufacturing application.

Single point incremental forming (SPIF) has higher formability limits than other sheet metal forming processes including stamping, and is therefore a desirable method of forming sheet metal components. To take advantage of this high formability it is necessary to understand how to maximise the limits through manipulation of parameters, increasing the likelihood of component success.In this paper, a systematic quantitative literature review was undertaken analysing experiments and results from 35 papers that studied the effect of process parameters on formability in SPIF. Collective results are presented regarding material thickness, tool diameter, tool shape and type, step down, feed rate, spindle speed and rotation direction, and some parameter interactions. The analysis provides evidence to support the hypothesis of an ideal operating range for each parameter and interdependency of parameters. A lack of focus in the literature on parameter interactions was found. A framework for important experimental parameters is proposed based on the review. Statement of originality: Quantitative analysis of research presented in the literature about parameter effects on formability in SPIF. (C) 2016 CIRP.

The supply chain for metals used in manufacturing is usually from premanufacture (mining). Energy impact needs to be considered, with it being one of the five stressors that impact the environment. In this paper the energy needs for crushing and milling (comminution) are presented. A brief comparison is made with the energy needs for recycling of large scale waste products such as automobiles. A simple method for product designers, which uses Streamlined Life Cycle Analysis, is proposed for assessment of mining value chain impacts.

The supply chain for metals used in manufacturing is usually from premanufacture (mining). Energy impact needs to be considered, with it being one of the five stressors that impact the environment. In this paper the energy needs for crushing and milling (comminution) are presented. A brief comparison is made with the energy needs for recycling of large scale waste products such as automobiles. A simple method for product designers, which uses Streamlined Life Cycle Analysis, is proposed for assessment of mining value chain impacts. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the scientific committee of the 23rd CIRP Conference on Life Cycle

Heat pump performance is always improving. Lower minimum operating temperatures and better performance curves are increasing both the number of hours of useful service and effectiveness while in use. We estimate the rate of technological development for residential air source heat pumps and their consequent rate of adoption using a system dynamics model. From the perspective of the use stage in life cycle assessment, energy savings and greenhouse gas emissions reductions are estimated. A substantial reduction in overall energy consumption is predicted, while greenhouse gas emissions are only reduced where electricity is generated with little or no fossil fuels.

An automotive engine cradle supports many crucial components and systems, such as an engine, transmission, and suspension. Important performance measures for the design of an engine cradle include stiffness, natural frequency, and durability, while minimizing weight is of primary concern. This paper presents an effective and efficient methodology for engine cradle design from conceptual design to detailed design using design optimization. First, topology optimization was applied on a solid model which only contains the possible engine cradle design space, and an optimum conceptual design was determined which minimizes weight while satisfying all stiffness constraints. Based on topology optimization results, a design review was conducted, and a revised model was created which addresses all structural and manufacturability concerns. Shape and size optimization was then performed in the detailed design stage to further minimize the mass while meeting the stiffness and natural frequency targets. Lastly, the final design was validated for durability. The initial design domain had the mass of 82.6 kg; topology optimization in conceptual design reduced the mass to 26.7 kg; and the detailed design task involving shape and size optimization further reduced the mass to 21.4 kg.

This paper presents an update on single point incremental forming (SPIF) of sheet metal since 2005. It includes a description of the process with new information on the maximum forming angle, \(\phi_{ \hbox{max} }\), for 5052-H32. An in-depth example of the successful design and production of parts is given for industry. This includes discussion on production times and surface roughness with details that will help designers. A general design guide for users of SPIF is provided. It is based upon experience gained in the last decade. In general, materials show a trend of decreasing formability with increasing initial thickness. It is shown that for thicker sheet metal, it is recommended using large spherical tools (12.7 mm or larger), or a large flat-ended tool. The flat-ended tool provides the best combination of good formability and very low surface roughness. For aluminum, galvanized steel and stainless steel, it is recommended using a flat-ended tool. Advances in multi-pass techniques and information on successful and useful numerical models which predict forming behaviour are included. Finally, there is a discussion on future work needed in SPIF.

The product material supply chain starts with stage 1 in manufacturing. In Life Cycle Analysis (LCA) or in an SLCA (streamlined LCA) this is premanufacture. Ideally the first stage starts with recycled material, however most material comes from mining, and will do so for the foreseeable future. The first stage has five elements: material, energy, solids, liquid and gas. Important considerations are water use (liquids), emissions (toxicity and carbon) and energy consumption. This paper considers energy use in mining extraction, in particular energy consumption by equipment such as LHD's (Load-Haul-Dump machinery) and by HVAC systems.

A high recovery of lithium from recycled lithium ion batteries (LIBs) is essential to ensure the growth and sustainability of the electrical vehicle market. Without recycling, lithium demand is predicted to outstrip supply in 2023. Current industrial processes are focused on recovering cobalt and other valuable metals because, given lithium's current low price, it is economically unfavorable to recover it. As part of our efforts to create a process where the recovery of lithium is economically viable we have analyzed the current industrial processes. We have determined that, when applied to recycling automotive LIBs, they are needlessly energy intensive and complicated. In these processes whole LIBs are incinerated, cryogenically cooled, or shredded under an inert atmosphere in order to make their cells safe to open. Instead of such extreme measures, LIBs can be disassembled by automated processes, which recovers valuable electronics for reuse, their cells can be discharged, which recovers residual energy, and then can be opened safely in air.

Because the deformation within single-point incremental forming occurs in a small region around the area of contact, understanding the size and shape of the contact patch is useful to model process conditions. The following presents a new model of contact geometry, wherein contact geometry is derived from the intersection of the tool with the regions that have already been formed. Because this method allows for contact geometry to be determined based on measurable surrounding features, experimental measurements of contact geometry are performed to quantify the contributions of tool diameter, step size and wall angle on contact area.

Improving the energy efficiency of industrial processes and the facilities in which they are carried out is often considered to be one of the most promising ways to begin reducing global greenhouse gas emissions. One of the best ways for organizations to reduce their energy consumption without having to carry out extensive equipment and facility overhauls is waste heat recovery or energy recycling. Waste heat recovery involves tapping into previously discarded thermal energy streams and reusing it for various purposes within a facility (space heating or cooling) or within the process itself (pre-heating air and boiler makeup water). Despite the numerous social and economic benefits that are available through waste heat recovery, several economic and technical barriers still exist to its wide-scale implementation. This paper provides an overview of the current state of waste heat recovery systems available in industry, offers a discussion of the major barriers to their wide-spread implementation, and lastly concludes with new data with several new case studies from Canadian manufacturers which have successfully harnessed waste heat within their facilities.

Single-point incremental forming is a sheet metal forming technique with great potential for use in prototyping and custom manufacture. While this process has undergone considerable development in recent years, designers may benefit from clear design rules to guide the process of designing for and implementing single-point incremental forming. This article presents simple design guidelines that translate forming limits into simple design constraints. A method of developing intermediate models for multi-pass forming is also documented. To demonstrate the utility of such simple design rules, examples of components that were made using this process are presented as case studies.