PROGRAMMA PRIN 2022 - BCALL PRIN2022 D.D. N.104 DEL 2 FEBRUARY 2022
PROJECT TITLE
Going beyond recycling: Reshaping of End-of LIFE components through advanced sheet metal forming processes (RELIFE)
CUP CODE D53C24004610001
Budget: € 64000
U.R. Coordinator
Antonio Piccininni
Other Research Units or any Sub-Units
University of Palermo
Polytechnic University of Marche
Project description
The RELIFE project (“Going beyond recycling: Reshaping of End-of-Life components through advanced sheet metal forming processes”) aims to develop an innovative circular economy approach for End-of-Life (EoL) metal components, based on their direct reuse through advanced sheet metal plastic deformation processes. In particular, the project analyses the potential of certain flexible processes (Flexible Sheet Metal Forming, FSMF), such as: a) Hydroforming (HF, both hot and cold), in which the sheet metal component is deformed under the action of a pressurised liquid; b) Single Point Incremental Forming (SPIF), in which the sheet metal component is locally and incrementally deformed by the action of a rotating punch following a predefined trajectory; c) Hot Gas Metal Forming (HGMF), in which the sheet metal component, once heated to a temperature above half the alloy’s melting temperature, is deformed under the action of pressurised gas. Regardless of the choice of the specific technological solution, the objective is to transform discarded components into new products without resorting to traditional recycling based on remelting. The approach integrates numerical modelling, characterisation of the alloys under study, environmental analysis (LCA) and the development of decision-support tools (decision-making tools) to efficiently design reshaping operations
Purpose
The main objective of the project is to overcome the limits of conventional recycling, reducing energy consumption and CO₂ emissions associated with metal production, through direct reuse strategies for end-of-life components. RELIFE aims to demonstrate the technical and environmental feasibility of reshaping as a sustainable alternative, developing design methodologies and tools that make it possible to select and optimize the most suitable forming processes according to the characteristics of the initial component and the desired final product. In this way, the project contributes to the transition toward more sustainable production models, in line with the principles of the circular economy.
Expected results
The project includes several key outcomes: (i) the definition of methodologies for inspecting and assessing the re-formability of end-of-life components; (ii) the development and validation of advanced numerical models to simulate reshaping processes; (iii) the identification of process windows and optimal parameters for the various FSMF processes; (iv) the quantification of environmental benefits compared with conventional recycling through LCA; and (v) the development of guidelines and decision-support tools for the industrial implementation of reshaping. Overall, RELIFE aims to provide a scientific basis and operational tools to promote the industrial adoption of advanced reuse strategies for end-of-life (EoL) metal components.
