Comparative Analysis on Sustainability Parameters of Traditional Tool Manufacturing Processes Using Life Cycle Analysis Tools

Abstract

Life Cycle Assessment (LCA) is a potent tool for evaluating the ecological consequences of various products and processes. However, with a plethora of LCA software tools (ST) available, selecting the most appropriate tool for a specific application can be quite challenging. This research paper aims to compare two popular LCA Tools, GaBi- a commercial software, and openLCA- an open-source, for a traditional tool manufacturing case study. The comparison considers factors such as userfriendliness, user support, modelling capability, cost, flexibility, comprehensiveness, and functionality. Impact categories representing human health, ecosystem, and resource consumption were chosen. The case study evaluated the Cradle-to-gate manufacturing of a turbine die made by traditional machining processes and used as a wax injection moulding die for investment casting. The study found that aluminum production and manufacturing were the highest contributors to total environmental impact due to electricity consumption and aluminium waste. The results indicate that each ST has unique features and capabilities suitable for specific applications. We calculated relative deviations as the ratio of maximum to minimum calculated impacts for comparison. Ozone depletion (22.57) and freshwater eutrophication (4.2) had the highest variation. Significant deviations in human toxicity (3.16) were observed using the ReCiPe, while climate change (1.58 and 1.66) was accurately assessed by both CML and ReCiPe. GaBi is found to be the most user-friendly and efficient tool for beginners, with great modelling capability and flexibility to handle complex systems, while openLCA is the most comprehensive tool for analyzing complex systems, grants functionality, and is freely available suggested for experienced users. This research paper provides a comprehensive evaluation of LCA ST for traditional tool manufacturing applications, which can help manufacturers make informed decisions in selecting the most suitable ST for their LCA needs.