Energy and Cost Estimation of a Feature-based Machining Operation on HRSA

Forward-looking manufacturing companies aim for sustainable production with low environmental footprint. This is true also for aerospace engine-makers, although their environmental impact mostly occurs during the use-phase of their products. Materials, such as Nickel alloys, are used for special applications where other materials will not withstand tough working conditions in terms of pressure and temperature. Heat Resistant Super Alloys are, however, considered difficult to machine and cutting tools will wear off rapidly. In this paper, a simple way to estimate the energy required, the cost and environmental footprint to produce a work piece using standard engineering software is presented. The results show that for a hypothetical 3 tonne work piece, Inconel 718 will be considerably cheaper and require less water but will require more energy, and has considerably larger CO2 footprint than Waspaloy.