Method for producing conical metal objects made of thin sheet metal

Abstract

The invention relates to a method for producing a component (3) made of an aluminum sheet with a thickness ranging from 0.05 to less than 0.08 mm and with a region (15) which is curved or linearly conical at least in some sections and which is made of a pot-shaped blank (1) with a substantially cylindrical wall section (7). The invention is characterized in that the method has at least the following steps: carrying out a drawing process (64) in steps and carrying out a conical drawing process (65) directly or indirectly following the drawing process, wherein prior to the drawing process (64), a stamped piece (46) is stamped (62) from the flat sheet metal, and the stamped piece is shaped into the pot-shaped blank (1), the free circumferential edge (10, 47) being expanded (47) in a conically curved manner at least in some sections; a circumferential radial flange (54) and an axial cylindrical edge region (52) are formed during the conical drawing process (65); and the conical drawing process (65) is followed by a drawing process (66) in which the expanded conical section (47) is folded in order to form a folded expanded section (74) for a form-fitting connection, and the axial cylindrical edge region (52) and the folded expanded section (74) are subsequently rolled from the bottom by means of a roller stamp (56) in order to form a rolled edge (55).

Description

[0001] TITLE METHOD FOR THE MANUFACTURE OF CONICAL METAL OBJECTS FROM

[0002] THIN SHEETS

[0003] TECHNICAL FIELD

[0004] The present invention relates to methods for producing a component from a thin metal sheet, wherein the component has an at least partially curved or linearly conical region and is formed from a cup-shaped blank with a substantially cylindrical wall section, as well as to devices for carrying out such a method and to components produced using the method. In particular, the method is suitable for the production of aerosol dome elements or capsules, particularly for food products, for example, for coffee.

[0005] STATE OF THE ART

[0006] Pot-shaped metal objects can be formed from a flat sheet of metal in a cold forming process. This typically occurs after a stamping process or combined with a stamping process in a single forming step (deep drawing), in which the finished component is given its final shape. Such processes are used, for example, for the production of pots, spray cans (or parts thereof), components in the automotive or furniture industries, food packaging, etc. Aluminum and tinplate are particularly used as materials.

[0007] Especially when using thin material thicknesses, the forming process must be carefully managed to avoid cracks, wrinkles, etc., and thus rejects or unsatisfactory quality. This applies especially to the formation of conical wall sections, because in contrast to the formation of axially cylindrical wall sections, the guidance in the tool is not guaranteed to the same extent.

[0008] US4,914,937 describes a method for forming a tapered container, in which the container is first drawn to a partial length having first and second straight sidewall sections connected by a transition section, and then redrawn to substantially its final length and tapered state by drawing material from the transition section. The method optionally also includes a second redrawing over the length and a bottom profiling step that uses the overdrawn section to form the profile.

[0009] EP-A-0310726 discloses a drawing process using a cylindrical punch and a frustoconical die. The blank is subjected to one or more drawing operations between a die with a frustoconical inner wall and a cylindrical punch, with the pressure of the clamping means being mitigated so that the metal conforms to the shape of the punch during deformation. The application for the production of can bodies from sheet metal using "double reduction" is also described.

[0010] EP-A-3702061 discloses a method for producing a component from a metal sheet having an at least partially curved or linearly conical region from a cup-shaped blank with a substantially cylindrical wall section. The method is characterized in that it comprises at least the following steps: a stepped drawing step, in which the cylindrical edge section of the blank is formed between a drawing die and a drawing punch displaceably guided in a fold holder into a stepped region with two cylindrical sections, and at least one subsequent conical drawing step, in which at least the stepped region is formed into the curved or linearly conical component section between two tools.

[0011] WO 2018 / 067013 describes a capsule containing a substance for preparing a drinkable beverage, the capsule comprising an aluminum capsule body with a side wall and an outwardly extending flange, and a sealing element on the outwardly extending flange for providing fluid sealing contact with an enclosing element of a preparation device. The beverage preparation device comprises an annular element having a free contact end, which may be provided with a plurality of radially extending open grooves. The sealing element is integral with the outwardly extending flange and has a projection. An annular groove between the inner projection base and the side wall has a bottom axially spaced from the outer projection base toward the bottom of the capsule body.

[0012] PRESENTATION OF THE INVENTION

[0013] A problem with the previously known methods is, among other things, that they are only suitable for materials above a certain thickness. If the material thickness is further reduced, for example, to save material, to work in a more ecologically sustainable manner, or to meet other requirements, problems arise, including cracking, uncontrolled deformation, etc. Accordingly, the subject of the present invention is to provide a method for producing a component from an aluminum sheet with a thickness in the range of 0.05 to less than 0.08 mm, with an at least partially curved or linearly conical region, from a cup-shaped blank with a substantially cylindrical wall section.

[0014] The proposed method is particularly characterized in that it comprises at least the following steps:

[0015] A step drawing process in which the cylindrical edge section of the blank is formed at least in sections between a drawing die and a drawing punch displaceably guided in a fold holder into a stepped region with two cylinder sections, a first cylinder section with a substantially axially extending circumferential wall with a first radius and a second cylinder section following along a component axis with a substantially axially or conically converging circumferential wall with a second radius which is smaller than the first radius.

[0016] The first and the second cylinder section are connected circumferentially via a transition section of the stepped area which runs essentially radially or tapers more conically than the second cylinder section.

[0017] The first cylinder section is guided at least partially on the inside by the fold holder in the step drawing process and is clamped between the fold holder and the drawing die, and the second cylinder section is formed by the drawing punch.

[0018] Furthermore, there is at least one directly or indirectly following conical drawing step, in which at least the transition section and the second cylindrical section of the stepped region are formed into the curved or linearly conical component section between two tools. The two tools are formed at least by a conical drawing die and a conical drawing punch movably guided in a conical drawing centering sleeve, and the first cylindrical section is guided in the conical drawing step, at least in part, by the conical drawing centering sleeve or is clamped and / or guided between the conical drawing centering sleeve and the conical drawing die. The transition section and the second cylindrical section and the transition section are formed between the conical drawing punch and the conical drawing die.

[0019] In this case, a circular blank is punched from a flat sheet before the step drawing, and this is formed in a subsequent forming step into a cup-shaped blank with a cylindrical wall section with a blank radius, wherein the free circumferential edge of the cup-shaped blank is curved at least in sections and widens conically (wherein this conical widening in the present case includes a radially extending flange with a bending angle a of up to 90° to the axial opening direction of the component).

[0020] Furthermore, a circumferential radial flange and an axial cylindrical edge area are formed in the cone on the opening side.

[0021] According to a first aspect of the present invention, the method is characterized in that, following the conical drawing, a drawing step is carried out in which the conical widening of the free circumferential edge (at least its outermost edge region) is folded in a form-fitting manner to a folding angle a of at least 100° to form a folded widening. Following the formation of the folded widening, the axial cylindrical edge region and the folded widening are rolled on the base side to form a rolled edge in an edge rolling process using a rolling die, wherein the rolled edge preferably protrudes beyond the plane of a flange formed in the conical drawing both on the base side and on the opening side.

[0022] According to a first preferred embodiment, the method is characterized in that a circumferential radial flange and an axial cylindrical edge region are formed on the opening side in the conical pass, and a groove pass is carried out following the conical pass, in which groove pass a bottom-side directed circumferential bead is formed between a shaped piece and a die, optionally in combination with a further shaped piece, and at the same time the conical widening of the free circumferential edge is folded over in a form-fitting manner to a folding angle a of at least 90° to form a folded over widening, and following the formation of the bead and the folded over widening, in a next step the axial cylindrical edge region and the folded over widening are rolled on the bottom side in an edge rolling process with a rolling die to form a rolled edge, wherein the rolled edge protrudes beyond the plane of the flange both on the bottom side and on the opening side.

[0023] In addition, it is possible and preferred that in the (grooving) process the conical widening of the free circumferential edge is folded in a form-fitting manner to a folding angle a of at least 110°, preferably to at least 120°, to form a folded widening, wherein the folded region is flat or preferably curved in the direction of curvature of the adjoining rolled edge.

[0024] The conical expansion typically has a radial width in the range of 0.5-2 mm, preferably in the range of 1-1.7 mm.

[0025] The process can be carried out particularly efficiently and safely if it is characterized in that in the (grooving) draw the conical expansion is held in a form-fitting manner between a folding punch and a die and rolled to the folded expansion.

[0026] According to a second aspect of the present invention, which can be used independently of the first aspect of the present invention as mentioned above, but is preferably used in combination with the first aspect, the method is characterized in that a further intermediate drawing is carried out between the step drawing and the conical drawing, in which the stepped region with two cylinder sections, the first cylinder section with a substantially axially extending circumferential wall having a first radius and the second cylinder section following along a component axis adjacent to the base with a substantially axially or conically converging circumferential wall having a second radius which is smaller than the first radius, is formed in such a way that a further step is formed from the base or from the base and the transition between the base and the second cylinder section, with a conical section or with a third cylinder section,whose radius is smaller than the second radius.,

[0027] In particular, this additional intermediate pull can largely prevent cracks and rejects when using the thin material under stress, but also in conjunction with starting material in the form of aluminum sheet with a thickness in the range of 0.05 to 0.1 mm.

[0028] Cracks in the material of the component can be prevented in particular if a third cylinder section is formed in the further intermediate draw, and in the further intermediate draw and / or in the step draw the height hi and the radius R2 of the second cylinder section and in the intermediate draw the height h2 and the radius R3 of the third cylinder section are selected in such a way that in the conical draw essentially from the beginning the convex inner curvature regions of the component come into contact with the outer contour of the conical draw drawing punch and essentially from the beginning the convex outer curvature regions of the component come into contact with the inner contour of the drawing die of the conical draw.

[0029] Preferably, the height hi of the second cylinder section is set as a multiple in the range of 0.8-1.2 of the height h2 of the third cylinder section.

[0030] The radii of the second and third cylinder sections are determined by the angle of the cone pull through the predetermined contact of the tool on the curved areas.

[0031] By specifically structuring the component or the mold used during the subsequent intermediate draw process, so that the punch and die come into contact at the appropriate contact points from the beginning of the subsequent taper draw process and remain in contact throughout the entire taper draw process, optimal material guidance is ensured and cracks are avoided. This allows even thinner material to be used, especially within the required thickness range of 0.05 to less than 0.08 mm, or with the thicker material described above, scrap can be significantly reduced.

[0032] Particularly few cracks and scrap are generated when the dimensions (height and radii of the steps of the second and third cylinder sections) are adjusted so that, essentially from the beginning of the cone drawing, the base of the component comes into contact with the lower surface of the cone drawing punch. This ensures controlled contact between the component to be machined and the tool on several surfaces from the very beginning of the cone drawing. The component material is drawn into the die via the base of the cone drawing punch, i.e., via its lower surface.

[0033] Such a method can further preferably be characterized in that in the further intermediate drawing the transition section and the second cylinder section are held in a form-fitting manner between a fold holder and the drawing die, and the conical section is formed by immersing a drawing punch guided in the drawing die into the base.

[0034] Typically, the transition section extends substantially circumferentially radially and the respective circumferential walls of the first and second cylinder sections extend substantially circumferentially axially.

[0035] Furthermore, it is possible that the cone pull centering sleeve is designed as a pleat holder, which clamps the first cylinder section and / or the transition section in the cone pull at least partially between the cone pull pleat holder and the cone pull drawing die.

[0036] According to a further preferred embodiment, the method is characterized in that the ratio of the radius of the first cylinder section to the radius of the second cylinder section is in the range of 2:1 - 1.1:1, preferably in the range of 1.6:1 - 1.25:1, particularly preferably in the range of 1.5:1 - 1.3:1.

[0037] And / or it is preferred that the ratio of radius of the first cylinder section to the bottom radius of the second cylinder section or of the cone section is in the range of 2.5: 1-1.2:1, preferably in the range of 2.0:1-1.4:1, particularly preferably in the range of 1.9: 1-1.5:1.

[0038] Furthermore, it is preferred if the ratio of the axial length of the first cylinder section to the axial length of the second cylinder section or of the second cylinder section and the cone section is in the range of 4:1 -0.5:1, preferably in the range of 3:1-0.75:1, particularly preferably in the range of 2.5:1-1:1.

[0039] It is also preferred if the ratio of the radius of the second cylinder section to the bottom radius of the cone section is in the range of 2.5:1-1.1:1, preferably in the range of 2.0:1-1.2:1, particularly preferably in the range of 1.9:1-1.3:1.

[0040] Typically, the proposed method is carried out in such a way that, prior to the step drawing, a preferably circular blank is punched, preferably in an alternating transversely offset manner, from a flat sheet, preferably supplied in the form of a strip, in particular from a roll, and this is then formed in a subsequent forming step to form a cup-shaped blank with a cylindrical wall section with a blank radius, wherein the free circumferential edge of the cup-shaped blank is either folded over to form a radial flange or is curved and widened conically, wherein the outer diameter of the widening is preferably 1-50 times the material thickness of the sheet larger than the blank radius, preferably in the case of a curved and conically widening circumferential edge is 2-20 or 5-15 times the material thickness of the sheet larger than the blank radius.

[0041] The blank is advantageously made of aluminum or an aluminum alloy with a tensile strength in the range of 80 - 120 MPa, in particular aluminum of the following types EN AW-8011A, 8079, 8176, 8021, 8090, sintered 6061, sintered 2014, each in uncoated form or in one-sided or two-sided, optionally colored, lacquered form.

[0042] Furthermore, the proposed method can be characterized in that the at least partially curved or linearly conical region has an average angle with the axis of symmetry of the component in the range of 5-40°, preferably in the range of 7-15°, particularly preferably in the range of 8-12°.

[0043] The at least partially curved or linearly conical region is preferably at least partially linearly conical, wherein it preferably has, apart from any steps that may be present, exclusively linearly conical regions.

[0044] In the conical drawing or in one or more subsequent forming steps on the bottom side, a further cylindrical or conical region, preferably connected via a radial region, can be formed adjacent to the at least partially curved or linearly conical region.

[0045] In particular, a further conical region is preferably formed in the cone section on the bottom side adjacent to the at least partially curved or linearly conical region, wherein this further conical region encloses a larger average angle with the axis of symmetry of the component than the at least partially curved or linearly conical region, preferably a cone angle in the range of 30-80°, in particular preferably in the range of 50-70°.

[0046] The method can further be characterized in that in a transfer station in several parallel processed paths, identical components are processed in parallel in the same stroke, preferably in at least two, particularly preferably 2-8, or 3-5 such parallel paths.

[0047] The roller drawing may be followed by further processing steps, in particular selected from the following group: punching steps; coating steps; application steps, in particular application of inserts or application of closures; filling steps; quality control steps; cleaning steps; assembly steps on further components, whereby these further steps are preferably carried out at least partly in the same transfer system as the step drawing and cone drawing,

[0048] Furthermore, the present invention relates to a device for carrying out a method as described above in the form of a transfer system with at least one station for the step drawing and a downstream station for the cone drawing, a downstream station for the groove drawing and a downstream station for the rolling, wherein the tool for the step drawing comprises a drawing die and a drawing punch displaceably guided in a pleat holder, and the first cylinder section and / or the transition section in the step drawing is clamped at least partially between the pleat holder and the drawing die and the second cylinder section and / or the transition section is formed by the drawing punch, and wherein the tool for the subsequent cone drawing comprises a cone drawing die and a cone drawing punch displaceably guided in a cone drawing centering sleeve,and the first cylinder section and / or the transition section in the cone drawing is guided and / or clamped at least partially between the cone drawing centering sleeve and the cone drawing die, and the transition section and / or the second cylinder section is formed between the cone drawing punch and the cone drawing centering sleeve.

[0049] Last but not least, the present invention relates to a component produced in a method as described above or in a device as described above

[0050] Further embodiments are specified in the dependent claims.

[0051] BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Preferred embodiments of the invention are described below with reference to the drawings, which are for illustrative purposes only and are not to be interpreted as limiting.

[0053] The drawings show:

[0054] Fig. 1: axial section through a workpiece in the various machining phases (aerosol dome); Fig. 2: the starting position for the intermediate pull in the tool for the aerosol dome;

[0055] Fig. 3 the intermediate pull end position in the tool for the aerosol dome;

[0056] Fig. 4 the starting position for the first pull on the aerosol dome;

[0057] Fig. 5 the final position of the first pull on the aerosol dome;

[0058] Fig. 6 shows a) a combined punching and forming station for punching the blanks and for forming them in the cut-and-draw process to form a coffee capsule blank in the open position (TDC); b) the tool according to Figure 6a) in the position in which the sheet metal is punched; c) the tool according to Figure 6a) in the closed position (UTDC), when the blank is deep-drawn;

[0059] Fig. 7 a) the tool for the intermediate pull during the production of the coffee capsule in the open state (OT); b) the tool for the intermediate pull during the production of the coffee capsule in the closed state (UT);

[0060] Fig. 8 a) the tool for the cone pull during the production of the coffee capsule in the open state (OT); b) the tool for the cone pull according to Figure 8a) in the half-closed state; c) the tool according to Figure 8a) in the closed state (UT);

[0061] Fig. 9 shows a section of the edge area of ​​the coffee capsule in the tool after grooving with an additional schematically drawn rolled edge;

[0062] Fig. 10 shows a section of the edge area of ​​the coffee capsule in the tool after completion of the rolling of the edge;

[0063] Fig. 11 the individual processing steps in the production of a coffee capsule;

[0064] Fig. 12 the upper edge area, wherein in a) the folded section after the cut-draw or after the step draw in the blank or the component after the step draw is shown, in b) the edge area in the tool for the groove draw, and in c) the finished edge area of ​​the capsule after the roller draw;

[0065] Fig. 13 shows the component after the further intermediate draw during the cone draw, where in a) the component after the further intermediate draw is shown in a partial section, in b) this component at the start of the cone draw when the punch comes into contact with the component, in c) the forming process in the tool when the bottom contour is formed, approximately 8 mm before the bottom dead center, and in d) the tool with the component held therein at the bottom dead center;

[0066] Fig. 14 the sequence of steps with the further intermediate pull and the formation of the folded widening in the grooved pull, with the areas circled in the lower sequence of steps being shown in detail at the top;

[0067] Fig. 15 in a) the opened tool for the further intermediate pull and in b) the closed tool for the further intermediate pull at bottom dead center;

[0068] Fig. 16 the opened tool for the cone pull with the component after the further intermediate pull;

[0069] Fig. 17 the half-closed tool for the conical drawing with the component after the further intermediate drawing;

[0070] Fig. 18 the open tool for the grooving for the production of the folded expansion;

[0071] Fig. 19 the tool for the groove pull at bottom dead center;

[0072] Fig. 20 the detail of the edge flange in the tool circled in Figure 19;

[0073] Fig. 21 the sequence of steps with the further intermediate pull and the formation of the folded widening in the groove pull according to a further embodiment of the method;

[0074] Fig. 22 in a) a schematic axial section through the tool for step 71 according to the sequence of steps in Figure 21 and in b) a schematic axial section through the tool for step 65 in Figure 21.

[0075] DESCRIPTION OF PREFERRED EMBODIMENTS

[0076] Figures 1-5 illustrate steps of the method proposed here using the various forming operations on a component.

[0077] Figure 1 shows an axial section through the workpiece in the various processing phases. Not shown is the first phase, in which the flat sheet metal section, a punched piece, is presented and formed. This punched piece is formed in a first step into the blank 1. This blank 1 is cylindrical and pot-shaped and has a folded-over edge section 10 in the form of a radial flange. This is followed by a circumferential cylindrical section 7 with radius Ri, a curved section 9 following this cylindrical section 7, and the bottom of the blank 1 is closed off by the bottom section 8, which runs perpendicular to the main axis 6, i.e. axially.

[0078] This blank 1 is first formed into a stepped component 2 in a first forming step, the intermediate draw or step draw. This stepped component now has a first cylindrical section 12 on the opening side, still with radius Ri, which transitions via a curved transition section 14 into a second cylindrical section 13 with a smaller radius R2. The area of ​​the transitions from 12 via 14 to 13 is also referred to as the stepped area 11. On the bottom side, adjoining the second cylindrical section 13 is a short curved area and then the bottom 25 of the component after the step draw with a bottom radius RB, which is defined as the radius of the flat area without the transition curvature to the second cylindrical section.

[0079] A second forming step then follows, in which this component 2 is formed into a conical component 3 in a first step, the actual conical step. The previously stepped area 11 is formed in this conical step into a curved conical area 15. This curved conical area 15 is followed by a base area. The base radius RB remains unchanged.

[0080] Then further drawing steps follow, in a second drawing to component 4 the cone angle is increased, thus the cone is formed more narrowly, and a cylindrical section 17 is formed in the bottom area.

[0081] In a final drawing step, the component 4 is further formed by forming the cylindrical region 17 into a radial region 18, which is followed on the bottom side by a cylindrical region 19, and on the bottom side the component is closed off by the base 20. This component 5 after the third drawing step is typically subsequently punched in the base area, and further operations can then follow, such as the formation of a rolled edge, etc.

[0082] The tools for implementing intermediate drawing and conical drawing to produce such a component are illustrated in Figures 2-5.

[0083] In the tool for intermediate or step drawing as illustrated in Figure 2, the blank 1 is guided into a drawing die 23 by a punch. The drawing die 23 forms the outer contour of the stepped area 11. The punch is constructed in two parts. An annular pleat holder 21 is arranged in a circumferential outer area. A cylindrical drawing punch 24 is displaceably mounted in this pleat holder 23. At the beginning of this step drawing, the front edge of the drawing punch 24 is essentially flush with the front edge of the pleat holder 21, and the front edge or plane of these lies essentially on the base section 8 of the blank 1. Now, as can be seen from Figure 3, the pleat holder 21 moves completely into the corresponding counter contour of the drawing die 23, so that the contact surface 22 of the pleat holder 21 clamps the curved section 9.Subsequently, or simultaneously, the drawing punch 24 moves further toward the base along the axis of symmetry 6, and the essentially axial outer contour of the drawing punch 24 now forms the second cylindrical section 13 of the stepped section 11, while the first cylindrical section 12 is clamped or at least guided between the pleat holder 21 and the drawing die 23. This creates a controlled taper to the newly created base region 25 with a smaller radius than the original base region 8, whereby cylindrical drawing is possible. In other words, the pleat holder 21 rests against the part at the beginning of this step drawing process, or at least during one phase of the step drawing process, thus preventing wrinkles from forming during forming. The drawing process is essentially cylindrical. At the end position of the step drawing process, the sheet metal is held comprehensively. The intermediate drawing process or step drawing process can be adjusted in height as required.The height of the intermediate pull / step pull can be adjusted to the geometry of the following conical pull.

[0084] The tool for the subsequent cone drawing is shown in Figure 4 in the position in which the forming process on the still stepped component 2 is just beginning. Here, there is a drawing die 27 and a radially outer annular fold holder 28 for the cone drawing, and in this, in turn, a drawing punch 29 for the cone drawing is movably mounted.

[0085] At the beginning of the formation of the conical area, the cylindrical first section 12 is already guided or even clamped between the centering sleeve 28 and the corresponding counter-contour with the cylindrical design of the drawing die. The centering sleeve 28 and, parallel to it, the drawing punch 29 for the conical drawing move into the drawing die, while simultaneously guiding and partially forming the first cylindrical section 12, and, above all, forming the transition section 14 and the second cylindrical section 13 by the conical contact surface 31 of the drawing punch 29.

[0086] The drawing punch then moves further than the centering sleeve 28 into the drawing die 27 until the conical contact surface 30 is reached, thus the conical region 15 between the surfaces 30 and 31 is formed, as can be seen in Figure 5.

[0087] The two radii at the beginning of this conical draw make the component more resistant to wrinkling. The two contact points between the drawing die and the drawing punch reduce the free edge. At the final position, the component is formed without wrinkling, at least for sufficiently thick materials, and is ready for the second draw.

[0088] Figures 6-8 illustrate the various tools for implementing the process using the example of producing a coffee capsule, for example, from polyester-coated aluminum sheet of type 8011A with a thickness of 0.1 mm. The surface weight of the aluminum is approximately 270 g / m 2 and the varnish (including primer) approx. 18 g / m 2 .

[0089] The complete process of producing the coffee capsule (sequence of steps) is shown in Figure 11 and should be brought forward in the description for a better understanding of the forming steps.

[0090] In a cutting line 63, a cup-shaped blank 1 is formed in a combined sequential punching and forming operation in one tool. It is also possible to first punch out only the flat blank in a first tool in a pure punching step 62 and then to form this into blank 1 in a subsequent tool. The cup-shaped blank 1 has a closed base section 8 and an opening; the wall 8 of the blank is cylindrical and thus runs axially circular all the way around. In this step, a slightly folded rim 47 is formed on the free upper edge in the sense of a conical widening to an angle of at most 20° to the axial direction for stabilization for subsequent transport and for preparation for rolling the rolled edge.

[0091] This blank 1 is then formed into the stepped component 2 in an intermediate draw or step draw 64. This stepped component now still has the folded edge 47 on the free edge, a first cylinder section 12 with the same radius as the original radius of the blank 1, but this changes approximately halfway up via a transition section 14 into a second cylinder section 13 with a smaller radius.

[0092] This stepped component 2 is formed in a conical section 65 into component 3 with a linearly conical section. A cylindrical edge region 52 remains, which has essentially the same radius as the original first cylindrical section 12. This transitions via a radial flange into the actual conical region 15 of component 3. The base is also formed with a second conical angle in a further conical region 69. Both conical regions are formed in this conical section.

[0093] In a subsequent step, the upper circumferential flange is further formed in a groove train 66, as will be detailed below.

[0094] This is followed by a step in which the still axially projecting edge is rolled in the edge rolling 67 to form a rolled edge 55.

[0095] This is followed by an embossing step 68, in which further structures can be embossed, for example labels but also special structuring of wall sections such as decorative grooves or similar.

[0096] The tool for a combined punching and forming step for producing the blank 1 from a supplied sheet metal is shown in Figure 6.

[0097] The tool is designed as a transfer station with an upper support plate 41 and a lower support plate 42. The plates are guided by guide cylinders 23 and can only be moved vertically relative to each other. Figure 6a shows the top dead center (TDC) of the tool. The forming steps are carried out with the opening of the component facing upwards. The strip is fed in as a sheet metal strip and held in place by a hold-down pin 40 and another hold-down pin 34 centered in the tool.

[0098] The upper support plate houses the drawing punch 35 for the drawing process, as well as the associated fold holder 33, which radially encloses the drawing punch. This fold holder 33 is also enclosed by a cutting ring 36 or a cutting die, whose task is to prepare the round, flat blank before the deep-drawing process. This cutting die 36 is carried by a support element 36a, which rests at the top dead center on a stop 36b of the corresponding guide 36d. The cutting ring 36 and the fold holder 33 are axially movable relative to each other to a small extent.

[0099] On the lower support plate 42, there is initially a lifter 39, radially outward, which is braced upwards by a spring 39. Following radially inward is the annular cutting punch 37 for the blanking process, which also serves as the deep-drawing die for forming the blank. Then, right in the center, is the ejector 38 for the blanking process. Figure 6b now illustrates the position in which the circular blank 46 is being punched out of the sheet metal strip. The upper support plate 41 lowers downwards, the cutting punch 37 is fixed in its position, whereas the lifter 39 can be pushed slightly downwards by the spring 39a. The front surfaces of the fold holder 33 and cutting die 36 now come into contact with the surface of the sheet metal. The cutting die 36 is fixed by the stop on the support element 36a, while the fold holder 33 can give way upwards slightly.As a result, the cutting ring 36, as can be seen in the enlargement at the bottom left in Figure 6b, plunges slightly deeper downwards, the fold holder 33 and cutting punch 37 clamp the sheet and the inner ring edge of the cutting ring 36 punches the sheet by plunging slightly downwards around the edge contour of the cutting punch 37.

[0100] There is no transfer to the next station; instead, the punched piece 46, thus held between the fold holder 33 and the cutting punch 37, is immediately formed into the blank 1 in the same station by moving the tool further downwards to the bottom dead center (BDC), which is illustrated in Figure 6c. The drawing punch 35 now moves into the annular recess in the cutting punch 37, with the ejector 38 being displaced downwards over the drawing punch 35. The pneumatic cylinder 38a constantly presses the base against the drawing punch 35. In this way, the cylindrical wall 7 of the blank 1 is formed between the drawing punch 35 and the cutting punch or deep-drawing die 37.At the same time, the upper circumferential inner edge of the deep-drawing die 37 is convexly curved and the drawing height is adjusted so that the above-mentioned slightly outwardly folded edge section 47 is formed on the blank 1, thus a short flange which widens somewhat in a trumpet shape to stabilize the blank 1 at the upper edge.

[0101] Now this blank 1 is transported to the next station with a transfer system, which now carries out the step pull 64, the corresponding tool is shown in Figure 7.

[0102] Here, again, there is an upper support plate 41 and a lower support plate 42. The upper support plate houses the fold holder 21 for the step draw, and the drawing punch 24 is mounted axially displaceably within it. In a central recess of this drawing punch, there is also a hold-down pin 48, which, with its guide pin 48a, is mounted axially displaceably in this central recess. The front surface of the drawing punch 24 has a concave front surface contour 24a, which corresponds to the rear convex contour of the hold-down pin in the frontmost extension area, so that when the hold-down pin 48 is in the fully retracted position in the drawing punch 24, these two elements together form a flush, radially extending front surface (see Figure 7b).

[0103] The lower drawing die 23 is provided as an annular element on the lower support plate 42 and is axially immovable. The ejector 49 is provided in this drawing die 23 and is axially movable. Figure 7a shows the tool for the step drawing at top dead center. The blank 1, which was transported to this station by a transfer device, now lies as blank 1 on the ejector 49, and the upper tool part moves downward. The blank 1 is initially clamped between the ejector 49 and the front surface of the hold-down pin 48. The fold holder 21 then moves into the upper recess of the blank, initially without any forming effect, which is facilitated by the slight widening 47.At the appropriate time for the desired drawing height for the first and second drawing stages, the drawing punch 24 also begins to move further downward than the front edge of the fold holder 21, and the stepped region is formed by the radial peripheral surface in the front area of ​​the fold holder 21 guiding the blank, the transition section 14 being formed at the upper edge of the drawing die, and the second cylindrical section being formed by the radial outer surface of the drawing punch and the radial inner surface of the drawing die. Figure 7b shows the tool for the stepped drawing at the bottom dead center reached.

[0104] The subsequent cone drawing 65 is realized in the tool shown in Figure 8. In Figure 8a, the tool for the cone drawing is shown at top dead center. Here, the upper support plate again has a fold holder 28, which is ring-shaped and whose position relative to the upper support plate is not fixed but axially movable. The drawing punch 29 for the cone drawing is formed in this fold holder 28. It has a double-conical outer contour, the actual first cone 29a for the actual conical area, and a further cone 29b for the conical formation of a base area 69.

[0105] In this drawing punch 29, a hold-down pin 15 is again provided, axially centered, which is mounted in the drawing punch so that it can move axially.

[0106] On the lower support plate, there is the annular drawing die 27, which provides the counter contour for the outer surface of the drawing punch 29. The counter surface for the second cone 29b is provided by the lower conical surface 27b, and the counter surface for the formation of the actual conical area over the surface 29a of the drawing punch is provided by the area 27a of the drawing die.

[0107] This drawing die 27 also features a movable ejector 51, which, just like the tool shown in Figure 7, serves, among other things, to push the finished component out of the tool from below when the upper plate is pushed upwards again, making it available to the grippers of the transfer system. The component after the step drawing 2 is now clamped between the hold-down pin 50 and the ejector as soon as it has been transferred from the transfer system to the position of this station, and then the upper part of the tool lowers further.

[0108] Figure 8b shows the position at which the actual forming process on component 2 begins. The fold holder 28 has already been retracted into the first cylindrical section 12 of component 2, and the drawing punch 29 has been displaced downwards, so to speak, to the bottom of component 2 with its frontmost surface. The actual forming process now begins when the tool is closed further and the drawing punch plunges further into the drawing die 27. In the process, the transition region 14 and the second cylindrical section 13 are first formed, and then the second cylindrical section 12 is also drawn further downwards into the mold, so to speak, until only a cylindrical edge region 52 is held by the outer contour of the fold holder in the fully closed position, as shown in Figure 8c.

[0109] The contours of the drawing punch 29 and the drawing die 27 now lie completely on top of each other, and the further conical area 69 has also formed, particularly in the base area.

[0110] This component 3 is now subjected to the operations already described above in connection with Figure 11; the tools for this are no longer fully shown.

[0111] Figure 9 shows only the flange area in the transfer tool for the grooving 66. The circumferential bead 53 is formed in this tool from above by a shaped piece 59, which is inserted into a die 58 with an internal shaped piece 60. In this step, the cylindrical edge area 52 and the folded edge 47 initially remain.

[0112] The rolled edge 55 shown in Figure 9 is only to be understood schematically; it is only created in the next tool or in a subsequent step in the same tool in the edge rolling 67, as shown in Figure 10. A roller stamp 56 with a correspondingly designed rolling contour 57 moves from above along a shaped piece 56 downwards, can optimally begin the rolling process due to the already slightly expanded upper contour 47 and folds the rolled edge 55 into a completely closed edge.

[0113] Coffee capsules can be produced in one or more stages, with or without a sealing groove. The material thickness used ranges from 90 microns (micrometers) to 120 microns. As described above, with this process, the rolled edge is fully formed in the rolling station without any preparation. When processing thinner 50 micron to 80 micron aluminum foil, the rolled edge can no longer be produced in the manner described above, as the even thinner material buckles in the edge rolling station, thus preventing an acceptable result. Furthermore, the wrinkling during the final drawing process becomes so severe that it can lead to sidewall tears and thus leaky capsules.

[0114] To form the rolled edge without damaging it (kinking), the rolling process must then be prepared. In the sequence of steps, a residual flange in the form of the conical expansion 47 described above remains on the part in the first station.

[0115] In front of the rolling station, this remaining flange or the conical widening 47 is formed in a form-fitting manner to approximately 120°, as shown in Figure 12.

[0116] In this figure, a) shows the edge region 47, as it is typically produced during the cutting process 63 to stabilize the upper free edge. Typically, this edge region is folded over by a maximum of 90° with respect to the axial direction (viewed in the opening direction of the container) to stabilize the upper edge during the processing steps and, for example, for the specified thin material with a thickness in the range of 0.05-0.08 mm, coated aluminum, has a substantially flat radial flange with a width RA in the range of 1-1.5 mm.

[0117] In the grooving tool shown in b), this conical expansion 47 is now formed (or rolled) into a folded expansion 74 by positively guiding the conical expansion between a die 58 and a folding punch 70. In this process, the original maximum angle of 90° with respect to the axial direction is folded to over 90°, typically to 100-120°, at least in the outermost radial edge area.

[0118] The folded widening 74 is then formed in the edge rolling 67 into the final flange, as shown in c).

[0119] By taking these measures, the rolling process in the rolling station can be carried out with a smaller initial force and the formation of kinks can be prevented.

[0120] In order to prevent sidewall cracks, the finished pull (conical pull) is prepared with an additional intermediate pull in addition to the existing step pull.

[0121] The intermediate draws (further intermediate draw and step draw) are adjustable in height so that the volumes can be distributed in such a way that the part has the greatest possible contact with the drawing die and the drawing punch at the start of the cone draw, as shown in Figure 13.

[0122] In a), component 2' is shown after the further intermediate pass 71. From top to bottom, the folded edge 47 or the conical widening, the adjoining first cylinder section 12, the transition section 14, and the subsequent second cylinder section 13 are visible. This is followed by a further conical section 73, which can also have an axial section, with a base 82', which then has a smaller diameter than the base of component 2 after the step pass.

[0123] If, as shown in b), the drawing punch 29 for the conical drawing now moves into this component 2' after the further conical drawing, the surface of the drawing punch 29 comes into contact with the component at a large number of contact points 75, which enables significantly improved guidance and prevents sidewall cracks. This guidance is maintained throughout the further drawing process, as can be seen with the drawing punch further immersed according to c), and ultimately leads to the closed tool according to d).

[0124] Figure 14 shows the sequence of steps with the additional elements for processing thinner aluminum sheets.

[0125] The blank 1 with the folded edge 47 is manufactured analogously to that shown above, if necessary with an edge of greater width and a folding angle of up to 90° (angle between the axis of symmetry in the opening direction of the component and the radially outermost section of the edge 47).

[0126] This component is formed into component 2 in the step train 64, also as described above.

[0127] Now, in deviation from the sequence of steps shown in Figure 11, a further intermediate pull 71 follows, in which a further conical section 73 is formed from the base 25, so that at the end a base 82' with a smaller radius than the base 25 results.

[0128] This is followed by the conical pass 65 as described above. This is followed by a groove pass 66, in which not only the groove is formed, but also, as already described above, the folded edge 47 is folded or rolled into a folded widened portion 74 with a folding angle a of more than 90°, here approximately 120°, with respect to the axial direction.

[0129] This is followed by edge rolling 67 as described above.

[0130] The sequence can be followed by further embossing steps or similar.

[0131] The new sequence of steps includes the following innovations:

[0132] To ensure stable edge rolling, the cutting pull is designed so that a residual flange of approximately 1.5 mm remains. The cutting pull itself remains the same and may be adjusted depending on the drawing height. The pleat holder 33 should be reversible via 33a.

[0133] This remaining flange is then tilted in a form-fitting manner in station 5. This process has three advantages, among others.

[0134] 1. The flange does not slip under the pleat holder, which also reduces the risk of chip formation in anisotropic materials.

[0135] 2. The positive pre-pressing of the rolled edge in station 5 ensures that the rolled edge is optimally rolled in rolling station 6.

[0136] 3. With this process, the contact of the rolled edge with the rolling die is made at the same time all the way around in the case of anisotropic material.

[0137] The additional intermediate draw ensures optimal preparation of the volumes and fewer wrinkles are created during the final draw, which can then lead to sidewall cracks.

[0138] Figure 15 shows in a) the tool for the further intermediate draw 71 in the open state. The component 2 after the step draw is located on the ejector 81 and is then held in position by the hold-down pin 77. The drawing die 80 is arranged on the lower side, and at the top around the hold-down pin 77 there is first the drawing punch 78, and around this the fold holder 79, which, as can be seen from the illustration of the closed tool in b), not only holds the machined component in the area of ​​the transition section 14 and the second cylinder section 13, but also controls the new transition to the conical section 73. The front contour of the drawing punch forms the conical section 73 from the base 25.

[0139] Figure 16 shows the open tool for the conical drawing, starting from component 2' after the further intermediate drawing, and not, as shown in Figure 8a, from component 2 after the step drawing. Particularly in the transition from this figure to Figure 17, in which the tool is shown in a semi-closed state, analogous to Figure 8b for the conical drawing, it can be seen how the further conical section 73 enables better contact between the drawing punch 29 and the component, thus enabling a more controlled process.

[0140] Figure 18 shows the open tool for the grooving 66, in which not only the groove 53 is formed, but also the folded edge 47 is shaped or rolled into a folded widening 74. For this purpose, there is a shaped piece 60 in the lower part of the tool, and around this a die 58, on the upper edge of which a shaping contour 82 is provided, which, in interaction with a corresponding inner contour 83 of the folding punch 70 forming the upper tool part, enables the controlled formation of the folded widening 74. Radially on the inside of the folding punch 70, first the shaped piece 59 is provided for forming the groove, and further inside the holding punch 76, in whose central bore the hold-down pin 50 is guided.

[0141] If the tool is closed, the position shown in Figure 19 results, in which the folded edge 47 is rolled in a controlled manner between the die 58 and the folding punch 70 by the two contours 82 and 83 to form the folded widening 74.

[0142] This is shown in detail in Figure 20 in a sectional view of the edge area in the tool for grooving.

[0143] Figure 21 shows another alternative sequence of steps with the additional elements for processing thinner aluminum sheets.

[0144] The blank 1 with the folded edge 47 is manufactured analogously to that shown above, if necessary with an edge of greater width and a folding angle of up to 90° (angle between the axis of symmetry in the opening direction of the component and the radially outermost section of the edge 47).

[0145] This component 1 is formed into component 2 in the step train 64, also as described above.

[0146] Now, in deviation from the sequence of steps shown in Figure 11 and in deviation from the sequence of steps shown in Figure 14, a further intermediate pull 71 is modified compared to Figure 14, in which a further cylinder section 84 with a radius R3 is formed from the base 25, so that again a base 82' with a smaller radius than the base 25 results at the end.

[0147] This is followed by the cone pull 65 as described above.

[0148] This is followed by a groove train 66, in which not only the groove is formed, but also, as already described above, the folded edge 47 is folded or rolled into a folded widening 74 with a folding angle a of more than 90°, here approximately 120°, with respect to the axial direction.

[0149] This is followed by edge rolling 67 as described above.

[0150] The sequence can be followed by further embossing steps or similar.

[0151] The new sequence of steps includes the following innovations:

[0152] To ensure stable edge rolling, the cutting pull is designed so that a residual flange of approximately 1.5 mm remains. The cutting pull itself remains the same and may be adjusted depending on the drawing height. The pleat holder 33 should be reversible via 33a.

[0153] This remaining flange is then tilted in a form-fitting manner in station 5.

[0154] Figure 22 now shows essential elements in which this variant differs from the one shown in particular in connection with Figure 14.

[0155] Figure 22a shows the tool in an axial section for step 71 according to the sequence of steps in Figure 21. The component 2 or 2' is drawn by the drawing punch 78 and the fold holder 79 encompassing it into the drawing die 80, which in this case is two-part, and the formation of the third cylinder section 84.

[0156] In contrast to the step sequence according to Figure 14, in other words, not a further conical section 73 is formed, but a further third cylindrical section 84.

[0157] The height hi of the second cylindrical section 13 and the height h2 of the third cylindrical section 84 as well as the radius R2 of the second cylindrical section 13 and the radius R3 of the third cylindrical section 84 are selected such that

[0158] • the upper inner convex transition 87 between the first cylindrical region 12 and the radially extending transition section 14 and

[0159] • the lower inner convex transition 87 between the second cylindrical region 13 and the curved or even radially extending transition region 14' during processing in step 65, which is shown in Figure 22b, both come into contact from the beginning with the outer contour 86 of the drawing punch 29 for the cone drawing, which moves into the component 2' in the cone drawing 65.

[0160] Furthermore, preferably in step 71 according to the sequence of steps in Figure 21, the component with the third cylinder section 84 is designed such that the bottom or the lower surface 92 of the conical drawing punch 29 comes into contact with the bottom 25 of the component 2' from the beginning. This ensures that as many contact points or contact surfaces as possible are already present at the beginning of the conical drawing and during the conical drawing between the drawing punch and the die, and accordingly the material is formed as gently as possible so that cracks can be prevented. Furthermore, the respective height and radius are designed such that

[0161] • the convex outer transition region 89 between the second cylindrical region 13 and the transition region 14',

[0162] • as well as the convex outer transition 90 between the third cylindrical region 84 and the base 82' during the processing in step 65 both come into contact simultaneously from the beginning with the drawing die 27 forming the counterpart to the holding punch 76, which is only shown schematically in Figure 22b (for illustration, the inner contour 27' of the corresponding drawing die is illustrated in Figure 22b by the finished component 85).

[0163] In particular, the height and radius of the second cylindrical section 13 can already be set in the intermediate pull 64, or can be preset in this intermediate pull 64 and set in the further intermediate pull 71 to the desired height and the desired radius for the optimally adjusted conical pull 65.

[0164] This method as shown in Figures 21 and 22 has, among other things, three advantages.

[0165] 1. The flange does not slip under the pleat holder, which also reduces the risk of chip formation in anisotropic materials.

[0166] 2. The positive pre-pressing of the rolled edge in station 5 ensures that the rolled edge is optimally rolled in rolling station 6.

[0167] 3. With this process, the contact of the rolled edge with the rolling die is ensured at the same time,

[0168] 4. The additional intermediate draw optimally prepares the volumes and contact points for the next processing step and fewer wrinkles are created during the cone draw, which can then lead to sidewall cracks.

[0169] LIST OF REFERENCE SYMBOLS

[0170] 1 blank 8 bottom section of 1

[0171] 2 Component after 9 curved section of 1 intermediate train / step train between 7 and 8

[0172] 2' component after another 10 folded edge section

[0173] Intermediate move of 1

[0174] 3 Component after first pull 11 stepped area of ​​2

[0175] 4 Component after second pull 11 ' stepped area of ​​2'

[0176] 5 Component after third pull 12 first cylinder section of

[0177] 6 axis of symmetry 11

[0178] 7 cylindrical section of 1 13 second cylindrical section of 11 27 transition section 31 conical contact surface of between 12 and 13 29 conical area of ​​3 32 circumferential front edge of conical area of ​​4 and 28 5 33 fold holder for cut-pull cylindrical area of ​​4 33a hold-down pin of 33 radial area of ​​5 34 hold-down pin cylindrical area of ​​5 35 drawing punch for cut-pull

[0179] Bottom of 5 36 cutting ring, cutting die

[0180] Fold holder for intermediate pull / 36a supporting element of 36 and

[0181] Step pull guide element of 33 contact surface of 21 36b OT stop of 36a

[0182] Drawing die for intermediate drawing / 36c UT stop of 36a

[0183] Step train 36d guide from 36a

[0184] Drawing punch for 37 cutting punches for cutting

[0185] Intermediate pull / step pull Pull and deep drawing die for a front surface contour of 24 Pull to form the bottom of 2 blanks Contact surface of 23 for 22 38 ejector for cut-pull

[0186] Drawing die for cone drawing 38a Stop element for 38 in UT

[0187] Inner contour of 27' 39 Lifter a upper conical inner surface 39a Spring of 39 of 27 40 Hold-down pin for b lower conical inner surface Empty station of 27 41 upper carrier plate

[0188] Centering sleeve / pleat holder for 42 lower support plate

[0189] Cone pull 43 Guide cylinder between a TDC stop of 28 41 and 42 b BDC stop of 28 44 curved edge area of

[0190] Drawing punch for conical drawing 37 a 1. Cone for conical 45 drive-on block

[0191] Area 15 46 Die cut b 2. Cone for conical 47 folded edge of 1

[0192] Bottom area 69 48 Hold-down pin Conical contact surface of 48a Guide pin of 48 Ejector 80 Drawing die

[0193] Hold-down pin 81 ejector

[0194] Ejector 82 Form contour for formationa TDC stop of 51 of the folded expansion cylindrical edge area at 58 of 3 82' bottom circumferential bead in 53 83 inner contour of circumferential radial flange folding die 70 rolled edge 84 third cylinder section of

[0195] Rolling punch 11 Rolling contour of 56 85 finished component Die 86 Outer contour of 76

[0196] Form piece 87 upper transition between form piece 12 and 14 Rolling die 88 lower transition between

[0197] Punching, possible separately, 13 and 73 / 84 unless the next 89 upper transition between step is designed as cut-pull 13 and 84 90 lower transition between cut-pull 84 and 82 step pull / intermediate pull 91 inner contour of the shaped piece finished pull / cone pull 60 groove pull 92 lower surface of 29 edge rolls

[0198] Embossing a folding angle further conical area hi height of the second

[0199] Transfer stamp cylinder section further intermediate pull h2 height of the third further step cylinder section

[0200] Cone section Li axial length of the first folded expansion cylinder section

[0201] Contact points from 29 to 2' l_2 axial length of the second

[0202] Holding stamp cylinder section or in

[0203] Hold-down pin case of component 2' of the

[0204] Drawing punch of the second cylinder section

[0205] Fold holder and the further conical area 73 / of the third

[0206] Ri radius of the first cylinder section 84

[0207] Cylinder section 12 RA radial width of the conical

[0208] R2 Radius of the second expansion

[0209] Cylinder section 13 RB bottom radius

[0210] R3 Radius of the cone section

Claims

PATENT CLAIMS 1. A method for producing a component (3) from an aluminum sheet with a thickness in the range of 0.05 to less than 0.08 mm, with at least a partially curved or linearly conical region (15), from a pot-shaped blank (1) with a substantially cylindrical wall section (7), characterized in that the method comprises at least the following steps: a step drawing (64) in which the cylindrical edge section (7) of the blank (1) is formed at least partially between a drawing die (23) and a drawing punch (24) slidably guided in a folding holder (21) into a stepped region (11) with two cylindrical sections (12, 13), a first cylindrical section (12) with a substantially axially extending circumferential wall with a first radius (R1) and a second,a second cylindrical section (13) extending along a component axis (6) with a circumferential wall extending substantially axially or conically and having a second radius (R2) that is smaller than the first radius (R1), wherein the first and second cylindrical sections (13) are connected circumferentially via a transition section (14) of the stepped area (11) which extends substantially radially or is more conically tapered than the second cylindrical section (13), and wherein the first cylindrical section (12) is guided at least partially on the inside of the stepped section by the pleat holder (21) and clamped between the pleat holder (21) and the drawing die (23), and the second cylindrical section (13) is formed by the drawing punch (24); at least one conical section (65) following directly or indirectly thereafter,in which at least the transition section (14) and the second cylindrical section (13) of the stepped area (11) are formed into the curved or linearly conical component section (15) between two tools (27-29), wherein the two tools are at least formed by a conical drawing die (27) and a conical drawing punch (29) slidably guided in a conical drawing centering sleeve (28), and wherein the first cylindrical section (12) in the conical draw (65) is at least partially guided internally by the conical drawing centering sleeve (28) or clamped and / or guided between the conical drawing centering sleeve (28) and the conical drawing die (27), and the transition section (14) and the second cylindrical section (13) and the transition section (14) between the conical drawing punch (29) and The cone-draw die (27) is formed, wherein a circular stamped part (46) is punched (62) from a flat sheet before the step draw (64),and this in a subsequent forming step (63) to a pot-shaped, A blank (1) with a cylindrical wall section (7) with blank radius (RR) is formed, wherein the free circumferential edge (10, 47) of the pot-shaped blank (1) is formed at least partially curved and conically widening (47), wherein a circumferential radial flange (54) and an axial cylindrical edge region (52) are formed on the opening side of the conical section (65), and a section (66) is subsequently formed on the conical section (65), in which the conical widening (47) of the free circumferential edge is positively folded over to a folding angle (a) of at least 100° to form a folded widening (74), and subsequently, following the formation of the folded widening (74), the axial cylindrical edge region (52) and the folded widening (74) are joined on the bottom side in an edge rolling (67) with a rolling die (56). rolled with a rolled edge (55),wherein preferably the rolled edge (55) projects beyond the plane of the flange (54) on both the bottom and opening sides and wherein a further intermediate section (71) is carried out between the stepped section (64) and the conical section (65), in which the stepped area (11) with two cylindrical sections (12, 13), the first cylindrical section (12) with a substantially axially extending circumferential wall with a first radius (Ri) and the second cylindrical section (13) following along a component axis (6) adjacent to the bottom (25) with a substantially axially or conically conical circumferential wall with a second radius (R2) that is smaller than the first radius (Ri), is formed such that a further step (72) is formed from the bottom (25) or from the bottom (25) and the transition between the bottom (25) and the second cylindrical section (13) with a conical section (73) or third cylindrical section (84) whose radius (R3) is smaller is the second radius (R2).

2. Method according to claim 1, characterized in that a circumferential radial flange (54) and an axial cylindrical edge region (52) are formed on the opening side of the conical section (65), and a groove section (66) is subsequently formed on the conical section (65), in which a bottom-oriented circumferential groove (53) is formed between a molded part (59) and a die (58), optionally in combination with a further molded part (60), and simultaneously the conical expansion (47) of the free circumferential edge is positively folded at least 90° to form a folded expansion (74), and subsequently, after the formation of the groove (53) and the folded expansion (74), the axial cylindrical edge region (52) and the folded expansion (74) are rolled on the bottom side in an edge rolling (67) with a rolling die (56) to form a rolled edge (55). wherein the rolled edge (55) projects beyond the plane of the flange (54) on both the bottom side and the opening side.

3. Method according to claim 1 or 2, characterized in that in the (groove) drawing (66) the conical expansion (47) of the free circumferential edge is positively folded to a folding angle (a) of at least 110°, preferably at least 120° to a folded expansion (74).

4. Method according to one of the preceding claims, characterized in that the conical expansion (47) has a radial width (RB) in the range of 0.5-2 mm, preferably in the range of 1-1.7 mm.

5. Method according to one of the preceding claims, characterized in that in the (groove) train (66) the conical expansion (47) is held in a form-fitting manner between a folding die (70) and a die (58) and rolled towards the folded expansion (74).

6. A method according to one of the preceding claims, characterized in that a third cylinder section (83) is formed in the further intermediate section (71), and in the further intermediate section (71) and / or in the step section (64) the height (hi) and radius (R2) of the second cylinder section (13) as well as the height (h2) and radius (R3) of the third cylinder section (83) are selected such that in the conical section (65) the convex inner curvature regions (87, 88) of the component (2') essentially from the beginning come into contact with the outer contour (86) of the conical section drawing die (29) and essentially from the beginning the convex outer curvature regions (89, 90) of the component (2') come into contact with the inner contour (27') of the drawing die (27) of the conical section (65), wherein preferably the height (hi) of the second cylinder section (13) is selected as a multiple in the range of 0.8-1 .2 the height (h2) of the third cylinder section (83) is set, and wherein the dimensions are further preferably set such that in the conical section (65) the bottom (25) of the component (2') comes into contact with the lower surface (92) of the conical section drawing die (29) essentially from the beginning.

7. Method according to claim 6, characterized in that in the further intermediate section (71) the transition section (14) and the second cylinder section (13) are positively locked between a pleat holder (79) and the drawing die (80), and the cone section (73) is formed by immersing a drawing punch (78) guided in the drawing die (80) into the base (25).

8. Method according to the preceding claims, characterized in that the transition section (14) extends substantially radially around its circumference and the respective circumferential walls of the first and second cylinder sections (12, 13) extend substantially axially around their circumference, and / or that the cone-draw centering sleeve (28) is designed as a pleat holder which clamps the first cylinder section (12) and / or the transition section (14) in the cone-draw (65) at least partially between the cone-draw pleat holder (28) and the cone-draw drawing die (27).

9. A method according to any one of the preceding claims, characterized in that the ratio of radius (Ri) of the first cylinder section (12) to radius (R2) of the second cylinder section (13) is in the range of 2:1–1.1:1, preferably in the range of 1.6:1–1.25:1, and particularly preferably in the range of 1.5:1–1.3:1; and / or that the ratio of radius (Ri) of the first cylinder section (12) to the base radius (RB) of the second cylinder section (13) or of the cone section (73) is in the range of 2.5:1–1.2:1, preferably in the range of 2.0:1–1.4:1, and particularly preferably in the range of 1.9:1–1.5:1; and / or that the ratio of the axial length (Li) of the first cylinder section (12) to the axial length (L2) of the second cylinder section (13) or of the second cylinder section (13) and the cone section (73) is in the range of 4:1 - 0.5:1, preferably in the range of 3:1 - 0.75:1, particularly preferably in the range of 2.5: 1-1 :1 and / or that the ratio of radius of the second cylinder section (13) to bottom radius (RB) of the cone section (73) is in the range of 2.5:1 - 1.1:1, preferably in the range of 2.0: 1-1.2:1, particularly preferably in the range of 1.9: 1-1.3:

1.

10. Method according to one of the preceding claims, characterized in that, prior to the step drawing (64), a preferably circular stamped part (46), preferably in an alternating transversely offset manner, is stamped (62) from a flat sheet, preferably supplied in the form of a strip, in particular from a roll, and this is formed in a subsequent forming step (63) into a pot-shaped blank (1) with a cylindrical wall section (7) with blank radius (RR), wherein the free The circumferential edge (10, 47) of the pot-shaped blank (1) is either folded over to form a radial flange (47) or is curved and conically expanding, wherein preferably the outer diameter (RF) of the expansion (47) is 1-50 times the material thickness of the sheet larger than the blank radius (RR), preferably in the case of a curved and conically expanding circumferential edge (47) is 2-20 or 5-15 times the material thickness of the sheet larger than the blank radius (RR).

11. Method according to one of the preceding claims, characterized in that the blank consists of aluminium or an aluminium alloy, with a tensile strength in the range of 80 - 120 MPa, in particular aluminium of the following types EN AW-8011A, 8079, 8176, 8021, 8090, sintered 6061, sintered 2014, each in uncoated or in one-sided or two-sided, optionally coloured form.

12. Method according to one of the preceding claims, characterized in that the at least partially curved or linearly conical region (15) has a mean angle in the range of 5-40°, preferably in the range of 7-15°, particularly preferably in the range of 8-12° with the axis of symmetry (6) of the component (3) and / or that the at least partially curved or linearly conical region (15) is formed at least partially linearly conical, preferably, apart from any steps that may be present, has exclusively linearly conical regions.and / or that in the conical section (65) or in one or more subsequent forming steps, a further cylindrical or conical section (19) is formed on the bottom side following the at least partially curved or linear conical section (15), preferably connected via a radial section (18), or, in particular, preferably, a further conical section (69) is formed on the bottom side following the at least partially curved or linear conical section (15) in the conical section (65), wherein this further conical section (69) encloses a larger mean angle with the axis of symmetry (6) of the component (3) than the at least partially curved or linear conical section (15), preferably a cone angle in the range of 30-80°, in particular preferably in the range of 50-70°.

13. Method according to any of the preceding claims, wherein characterized in that in a transfer station, identical components (3) are processed in parallel in the same stroke in several parallel processed lanes, preferably in at least two, in particular preferably 2-8, or 3-5 such parallel lanes, and / or that further processing steps follow the roller conveyor (67), in particular selected from the following group: punching steps; coating steps; application steps, in particular application of inserts or application of closures; filling steps; quality control steps; cleaning steps; assembly steps on further components, wherein these further steps are preferably carried out at least partially in the same transfer system as the step conveyor (64) and the cone conveyor (65).

14. Device for carrying out a method according to one of the preceding claims in the form of a transfer system with at least one station for the step drawing (64) and a downstream station for the cone drawing (65), a downstream station for the groove drawing (66) and a downstream station for the rolling (67), wherein the tool for the step drawing (64) comprises a drawing die (23) and a drawing punch (24) slidably guided in a pleat holder (21), and the first cylinder section (12) and / or the transition section (14) in the step drawing is clamped at least partially between the pleat holder (21) and the drawing die (23) and the second cylinder section (13) and / or the transition section (14) is formed by the drawing punch (24);and wherein the tool for the subsequent cone draw (65) comprises a cone draw die (27) and a cone draw punch (29) slidably guided in a cone draw centering sleeve (28), and the first cylindrical section (12) and / or the transition section (14) in the cone draw is guided and / or clamped at least partially between the cone draw centering sleeve (28) and the cone draw die (27), and the transition section (14) and / or the second cylindrical section (13) is formed between the cone draw punch (29) and the cone draw centering sleeve (27).

15. Component manufactured in a method according to one of the preceding claims or in a device according to claim 14.

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