An energy efficiency analysis of single point incremental forming as an approach for sheet metal based component reuse

Producing materials causes about 25% of all anthropogenic CO2 emissions. Metals play a significant role, steel and aluminum account for 24% and 3% of worldwide material related emissions respectively. Fostering resources efficiency strategies in the field of sheet components could lead to a significant environmental impact reduction. Reshaping could be one of the most efficient strategy to foster material reuse and lower the environmental impact due to material production. Specifically, for aluminum recycling, the overall energy efficiency of conventional route is very low and, more importantly, permanent material losses occur during re-melting because of oxidation. The present paper aims at presenting the technical feasibility of Single Point Incremental Forming (SPIF)-based reshaping approach. Change in shape of aluminum stamped part is obtained through SPIF process implementation. Preliminary energy savings quantification through life cycle energy and material flows modelling are provided, energy efficiency of conventional recycling approach and SPIF-based reshaping routes are analyzed and compared