Abstract: Firstly the idea of green design was introduced and applications in additive manufacturing were presented. Aiming at the bottlenecks of long process and high energy consumption of traditional manufacturing methods to make forgings parts with high performance, and a green manufacturing technology was proposed to make forging parts with ultra-short process hybrid micro casting forging and milling technology. Finally, taking an aero-engine forging part as an example, the calculation results show that the energy consumption of the traditional manufacturing method is 33.3 times of the energy consumption of micro casting forging and milling, and material consumption is 6.7 times of the micro casting forging and milling technology. Micro casting forging and milling provides a green material and energy saving manufacturing way with innovative ultra-short process to manufacture large complex forgings in China.

Key words: green manufacturing, micro casting forging and milling, super short-process, energy consumption

摘要： 基于绿色设计体系结构分析了绿色设计制造理念在增材制造技术中的体现，针对高端金属零件传统制造工艺流程长与能耗高这两个瓶颈问题，提出一种金属零件微铸锻铣复合超短流程绿色制造方法，并以一航空起落架外筒零件的制造过程为例，通过理论计算比较了新方法与传统方法的能源和材料消耗。研究结果表明：制造该外筒零件，传统制造方法与微铸锻铣复合制造方法相比，前者的能耗是后者的33.3倍，前者的材料消耗为后者的6.7倍，后者的生产周期由数月缩短为数天。该方法的提出，为我国大型复杂锻件的生产提供了一种超短流程、节能省材的绿色制造新模式。

关键词: 绿色制造, 微铸锻铣, 超短流程, 能耗