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Activities of the JSTP Committee on Environmental Issues
Jounl~ of
ELSEVIER
Journal of Materials Processing Technology 59 (1996) 183-185
Ma, erials Processing Technology
Activities of the JSTP Committee on Environmental Issues Toshio Sano a.*, Ken-ichi Kawai b " Mechanical Engineering Laboratoo,, AIST, MITI, Namiki 1-2, Tsukuba, ibaraki 305, Japan b Department of Mechanical and Materials Science, Yokohama National UniversiO', Yokohama, Japan Received 1 March 1995
Industrial summary
In 1990, the Japanese Society for the Technology of Plasticity (JSTP) launched the Committee on Enironmental Issues. About forty Committee members reviewed global environmental issues and looked at possible contributions by metal-forming technologies. The main areas of activity are resource conservation, energy conservation, vibration and noise, environmental pollutants, and recycling of resources. Methods for environmental impact assessment should be developed soon, and international cooperation for the development is proposed. Keyn'ords: Environment
1. introduction
It is said that changes in the global environment began after the industrial revolution, this tendency having accelerated since the 1950s. In 1972, the first conference on the environment was held by the United Nations. The second conference, the United Nations Conference on the Environment and Development (UNCED), was held in Rio de Janeiro in 1992. At this latter conference, international agreement on the concept of 'sustainable development' was reached. To realize the concept, environmental measures should be taken into consideration, even in metal-forming technologies. Environmental impact assessment has been conducted in terms of energy consumption, CO2 emission, usage of toxic materials, etc. As far as energy consumption is concerned, for example, Japan has developed one of the most effective industrial structures for energy saving, after the experience of the two oil crises. The metal-forming industry in Japan also experienced the same crises, and has examined energy saving, as well as productivity and product quality. However, further improvements are necessary. The relationship between plastic working and the global environment is not obvious. Furthermore, the environmental impact assessment necessary for the tech* Corresponding author. 0924-0136/96/$15.00 © 1996 Elsevier Science S.A. All rights reserved S S D I 0924-0136(95)02129-A
nology development should be carried out over the whole life cycle of products, including production, processing, usage and recycling, etc., which makes it more difficult to find suitable counter-measures in plastic working. In addition, the metal-forming industry is considered a typical pollution-causing industry, and many problems are left unsolved. Although the uncertainty about the relationship between plastic working and global environmental problems still remains, researchers should tackle these difficult problems, as well as those of pollution. Currently, the most important issues are to know which studies should be carried out urgently, and to establish an international cooperative framework. To cope with these situations, the Japanese Society for the Technology of Plasticity (JSTP) set up the Committee on Environmental Issues in 1990. The outline of the committee's activities is shown briefly here.
2. Activities of the Committee on Environmental Issues
1990 was called ~the first year of the environment in Japan'. People began to take an interest in the global environment, and many R&D projects were started in the private sector and in government institutes. International cooperation in many fields was also started in that year.
184
T. Sano, K. Kawai/ Jom'md of Materials Proces~#tg Technology 59 (1996) 183-185
The Committee on Environmental Issues started its activity in December 1990, seeking contributions to the solution of environmental problems, including those of pollution. The members of the Committee consisted of about forty specialists in metal forming and environmental issues. Since the establishment of the Committee, several meetings have been held so far to deepen knowledge of the global environment, and to promote contributions to that knowledge through metal forming. The activities and the results obtained are shown briefly. 2.1. Resource conservation
To improve the yield in metal forming, technologies to achieve high precision and net-shape forming, and high reliability in the process, are important. However, the excessive pursuit of quality should be avoided from an environmental point of view. Metal forming is a material-saving process compared with other shaping processes such as machining, and an increase in the adoption of metal-forming processes would contribute to the well-being of the environment. The development of novel/advanced metal-forming technologies is useful for this pupose. 2.2. Energy conservation
In metal forming, lowering the forming temperature and widening the applicable area of low-temperature forming are the direct measures taken to reduce the energy consumption. In general, however, heating and heat-treatment prior to, or after, metal-forming processes consume larger amounts of energy than that of the actual metal tbrming itself Therefore, the energy consumption throughout the process should be reviewed, Advanced metal-forming technologies useful for energy conservation snould also be developed. The utilization of more aluminium alloys in the automobile, for example, is useful for reducing fuel consumption. However, the formability and the accuracy of aluminium are low compared with high-tensile steel, which limits the usage of alumi,aium alloys in the automotive industry. Therefore, the urgent development of forming technologies for aluminium alloys, together with material development, are indispensable. 2.3. Vibration and noise
Statistics concerning pollution in Japan show that vibration and noise are very serious, accounting for 28.8% of all complaints in 1989. Most of the pollution was caused by metal-forming processes such as stamping and forging. Counter-measures should be taken, mainly for sources, propagation and receivers. As for
stamping and forging machines, both passive and active methods for suppressing the vibration and noise should be introduced. 2.4. Environmental polhaants
Chemical substances involved in lubricants, coolants, washing and surface-treatment agents, etc., cause environmental pollution. Oils such as lubricating oils are disposed of by, for example, incineration. Usually, sulfur, chlorine and phosphor are added to the lubricants as extreme pressure agents, and anti-pollution measures for these substances should be employed. Soluble graphite is used as the lubricant in hot forging. However, white or colorless lubricants should be used for an improvement in the working environment. Formed parts are usually cleaned using such washing agents as trichloroethane, which causes destruction of the ozone layer, but the development of alternative agents is underway. 2.5. RecyclflTg of resources
The recycling of steel is estimated to reduce energy consumption by 60-70%, waste by 95% and air pollution by 30%, compared with the production of steel from ores. In the case of aluminium, these values are evaluated to be 90-95%, 100%, 95%, respectively. In Japan, more than 99% of metal wastes produced in factories are recycled. However, the recycling percentage of used metal is relatively low due to the uncertainty of its contents, difficulties in refining, and lack of recycling systems. Since the enforcement of the Law on Promoting Utilization of Recycling Resources (October 1991), the configurations and materials for automobiles, electrical appliances, etc., are being forced to change for recycling. Forming technologies for recycled materials should now be given serious study.
3. International collaboration
The connection between metal-forming technology and environmental issues is recognized intuitively. However, the connection is sometimes not clear. Quantitative evaluation of the effect of metal-forming technology on the environment is very important for environmental measures and R&D. However, few studies have been done up to now. On the basis of the above understanding, the Committee on Environmental Issues proposes the international collaboration described below. (1) Development of evaluation methods (equations): (i) Selection of evaluation items (energy consumption, toxic/harmful substance, etc.).
T. Sano, K. Kau'ai / Journal of Materials Processhtg Technology 59 (1996) 183-185
(ii) Methods for each/common metal-forming technology. (iii) Methods for whole production systems. (iv) Methods including product life. (2) Execution of the evaluation for the typical parts, and evaluation of conventional/new metal-forming technologies. (3) Formation of an international collaboration system including continuous international meetings.
4. Conclusions
When the environmental issues were pointed out initially, engineers approached these problems with
185
different attitudes, suspicious, pessimistic and optimistic attitudes being typical. Presently, the seriousness of these problems is recognized, and the extreme optimists have disappeared. According to a recent questionnaire completed by 3000 staff working in manufacturing industries, government organizations and universitie3 in Japan, more than 95% of those questioned think that urgent R&D on environmental issues is necessary. Metal forming is, thus, not an exception. The JSTP Committee on Environmental Issues will continue to make efforts to give useful environment-related information to scientists and engineers specializing in metal-forming technologies, using international collaboration.
ELSEVIER
Journal of Materials Processing Technology 59 (1996) 183-185
Ma, erials Processing Technology
Activities of the JSTP Committee on Environmental Issues Toshio Sano a.*, Ken-ichi Kawai b " Mechanical Engineering Laboratoo,, AIST, MITI, Namiki 1-2, Tsukuba, ibaraki 305, Japan b Department of Mechanical and Materials Science, Yokohama National UniversiO', Yokohama, Japan Received 1 March 1995
Industrial summary
In 1990, the Japanese Society for the Technology of Plasticity (JSTP) launched the Committee on Enironmental Issues. About forty Committee members reviewed global environmental issues and looked at possible contributions by metal-forming technologies. The main areas of activity are resource conservation, energy conservation, vibration and noise, environmental pollutants, and recycling of resources. Methods for environmental impact assessment should be developed soon, and international cooperation for the development is proposed. Keyn'ords: Environment
1. introduction
It is said that changes in the global environment began after the industrial revolution, this tendency having accelerated since the 1950s. In 1972, the first conference on the environment was held by the United Nations. The second conference, the United Nations Conference on the Environment and Development (UNCED), was held in Rio de Janeiro in 1992. At this latter conference, international agreement on the concept of 'sustainable development' was reached. To realize the concept, environmental measures should be taken into consideration, even in metal-forming technologies. Environmental impact assessment has been conducted in terms of energy consumption, CO2 emission, usage of toxic materials, etc. As far as energy consumption is concerned, for example, Japan has developed one of the most effective industrial structures for energy saving, after the experience of the two oil crises. The metal-forming industry in Japan also experienced the same crises, and has examined energy saving, as well as productivity and product quality. However, further improvements are necessary. The relationship between plastic working and the global environment is not obvious. Furthermore, the environmental impact assessment necessary for the tech* Corresponding author. 0924-0136/96/$15.00 © 1996 Elsevier Science S.A. All rights reserved S S D I 0924-0136(95)02129-A
nology development should be carried out over the whole life cycle of products, including production, processing, usage and recycling, etc., which makes it more difficult to find suitable counter-measures in plastic working. In addition, the metal-forming industry is considered a typical pollution-causing industry, and many problems are left unsolved. Although the uncertainty about the relationship between plastic working and global environmental problems still remains, researchers should tackle these difficult problems, as well as those of pollution. Currently, the most important issues are to know which studies should be carried out urgently, and to establish an international cooperative framework. To cope with these situations, the Japanese Society for the Technology of Plasticity (JSTP) set up the Committee on Environmental Issues in 1990. The outline of the committee's activities is shown briefly here.
2. Activities of the Committee on Environmental Issues
1990 was called ~the first year of the environment in Japan'. People began to take an interest in the global environment, and many R&D projects were started in the private sector and in government institutes. International cooperation in many fields was also started in that year.
184
T. Sano, K. Kawai/ Jom'md of Materials Proces~#tg Technology 59 (1996) 183-185
The Committee on Environmental Issues started its activity in December 1990, seeking contributions to the solution of environmental problems, including those of pollution. The members of the Committee consisted of about forty specialists in metal forming and environmental issues. Since the establishment of the Committee, several meetings have been held so far to deepen knowledge of the global environment, and to promote contributions to that knowledge through metal forming. The activities and the results obtained are shown briefly. 2.1. Resource conservation
To improve the yield in metal forming, technologies to achieve high precision and net-shape forming, and high reliability in the process, are important. However, the excessive pursuit of quality should be avoided from an environmental point of view. Metal forming is a material-saving process compared with other shaping processes such as machining, and an increase in the adoption of metal-forming processes would contribute to the well-being of the environment. The development of novel/advanced metal-forming technologies is useful for this pupose. 2.2. Energy conservation
In metal forming, lowering the forming temperature and widening the applicable area of low-temperature forming are the direct measures taken to reduce the energy consumption. In general, however, heating and heat-treatment prior to, or after, metal-forming processes consume larger amounts of energy than that of the actual metal tbrming itself Therefore, the energy consumption throughout the process should be reviewed, Advanced metal-forming technologies useful for energy conservation snould also be developed. The utilization of more aluminium alloys in the automobile, for example, is useful for reducing fuel consumption. However, the formability and the accuracy of aluminium are low compared with high-tensile steel, which limits the usage of alumi,aium alloys in the automotive industry. Therefore, the urgent development of forming technologies for aluminium alloys, together with material development, are indispensable. 2.3. Vibration and noise
Statistics concerning pollution in Japan show that vibration and noise are very serious, accounting for 28.8% of all complaints in 1989. Most of the pollution was caused by metal-forming processes such as stamping and forging. Counter-measures should be taken, mainly for sources, propagation and receivers. As for
stamping and forging machines, both passive and active methods for suppressing the vibration and noise should be introduced. 2.4. Environmental polhaants
Chemical substances involved in lubricants, coolants, washing and surface-treatment agents, etc., cause environmental pollution. Oils such as lubricating oils are disposed of by, for example, incineration. Usually, sulfur, chlorine and phosphor are added to the lubricants as extreme pressure agents, and anti-pollution measures for these substances should be employed. Soluble graphite is used as the lubricant in hot forging. However, white or colorless lubricants should be used for an improvement in the working environment. Formed parts are usually cleaned using such washing agents as trichloroethane, which causes destruction of the ozone layer, but the development of alternative agents is underway. 2.5. RecyclflTg of resources
The recycling of steel is estimated to reduce energy consumption by 60-70%, waste by 95% and air pollution by 30%, compared with the production of steel from ores. In the case of aluminium, these values are evaluated to be 90-95%, 100%, 95%, respectively. In Japan, more than 99% of metal wastes produced in factories are recycled. However, the recycling percentage of used metal is relatively low due to the uncertainty of its contents, difficulties in refining, and lack of recycling systems. Since the enforcement of the Law on Promoting Utilization of Recycling Resources (October 1991), the configurations and materials for automobiles, electrical appliances, etc., are being forced to change for recycling. Forming technologies for recycled materials should now be given serious study.
3. International collaboration
The connection between metal-forming technology and environmental issues is recognized intuitively. However, the connection is sometimes not clear. Quantitative evaluation of the effect of metal-forming technology on the environment is very important for environmental measures and R&D. However, few studies have been done up to now. On the basis of the above understanding, the Committee on Environmental Issues proposes the international collaboration described below. (1) Development of evaluation methods (equations): (i) Selection of evaluation items (energy consumption, toxic/harmful substance, etc.).
T. Sano, K. Kau'ai / Journal of Materials Processhtg Technology 59 (1996) 183-185
(ii) Methods for each/common metal-forming technology. (iii) Methods for whole production systems. (iv) Methods including product life. (2) Execution of the evaluation for the typical parts, and evaluation of conventional/new metal-forming technologies. (3) Formation of an international collaboration system including continuous international meetings.
4. Conclusions
When the environmental issues were pointed out initially, engineers approached these problems with
185
different attitudes, suspicious, pessimistic and optimistic attitudes being typical. Presently, the seriousness of these problems is recognized, and the extreme optimists have disappeared. According to a recent questionnaire completed by 3000 staff working in manufacturing industries, government organizations and universitie3 in Japan, more than 95% of those questioned think that urgent R&D on environmental issues is necessary. Metal forming is, thus, not an exception. The JSTP Committee on Environmental Issues will continue to make efforts to give useful environment-related information to scientists and engineers specializing in metal-forming technologies, using international collaboration.