Modeling and Assessment of Carbon Emissions in Additive-Subtractive Integrated Hybrid Manufacturing Based on Energy and Material Analysis

In order to cope with the global challenge of climate changes, which transcends national boundaries, it has become a global consensus to vigorously promote carbon emissions reduction. This will bring extensive and profound changes to the manufacturing industry. As an advanced manufacturing technology, additive-subtractive integrated hybrid manufacturing (ASIHM) is not only suitable for manufacturing complex parts but also offers significant advantages in terms of material utilization and production efficiency. In this paper, carbon emission modeling and a case study are conducted to assess the carbon emission characteristics of ASIHM quantitatively. Firstly, the research system boundary was delineated based on the life cycle theory. Secondly, the precise model of carbon emissions was established according to the equipment operating status and process characteristics. Then, the carbon emissions of the ASIHM process were analyzed, and comparative research on the carbon emissions in material and energy consumption was also carried out with the conventional subtractive manufacturing (CSM) process. The results have revealed that ASIHM has the highest proportion of carbon emissions during the additive forming stage, reaching over 54%. Compared to conventional milling, ASIHM has an 80% lower carbon footprint.