Bottomed Can Blanking with Buffer Holes to Prevent Warpage
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Solution Overview
Problem
Existing methods for manufacturing bottomed cans through drawing and ironing face challenges such as distortion and warpage due to coining before punching, leading to positioning issues and increased scrap rates.
Innovation Solution
A method involving coining at least part of the area to be blank on a metal raw plate, followed by piercing a material flow buffering hole to absorb material expansion, thereby preventing distortion and allowing for precise punching and forming into a bottomed can shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coining is performed on the strip-shaped raw plate before punching the blank, then the material can be thinned in advance to reduce ironing rate and suppress body burst, but the material is extruded during coining causing distortion and warpage that interferes with positioning during subsequent punching
Solution Approach 1:
The buffering hole is formed in advance before coining, creating a predetermined space that guides material flow during the coining process. This preliminary action prevents uncontrolled material extrusion and distortion while maintaining positioning accuracy for subsequent punching operations.
Solution Approach 2:
The buffering hole acts as an intermediary space that mediates between the coining pressure and the surrounding material. It provides a controlled path for material displacement, preventing direct extrusion that causes distortion and warpage while maintaining the integrity of positioning features.
2Strength
If coining is performed on the strip-shaped raw plate to thin the material, then the ironing rate can be reduced to suppress body burst, but distortion occurs that spreads to adjacent areas to be blank, requiring a large distance between areas and increasing scrap
Solution Approach 1:
The buffering hole segments the continuous material flow into controlled regions, isolating the distortion effect to the immediate vicinity of the hole. This segmentation prevents distortion from spreading to adjacent blank areas, allowing closer spacing of blank regions and reducing scrap material.
Solution Approach 2:
The buffering hole serves as an intermediary zone that absorbs and contains material displacement during coining. By providing this intermediate space, the harmful distortion effect is localized and prevented from propagating to adjacent areas, maintaining both strength improvement and material efficiency.
3Measurement precision
If a large distance is ensured between areas to be blank to prevent distortion spreading, then positioning accuracy is maintained, but the amount of scrap increases and productivity decreases
Solution Approach 1:
The buffering hole is created in advance to establish controlled material flow paths before coining occurs. This preliminary structure enables closer spacing of blank areas while maintaining positioning accuracy, as the hole pre-defines where material displacement will occur without affecting adjacent regions.
Solution Approach 2:
The buffering hole segments the material flow and distortion zones, allowing adjacent blank areas to be positioned closer together. By containing distortion locally around the buffering hole, the effective usable width of the raw plate increases, reducing scrap and improving productivity while preserving positioning accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in high-quality bottomed cans with reduced distortion and warpage, improved positioning accuracy, and decreased scrap rates, enhancing productivity in the manufacturing process.
Implementation Method 1
piercing a material flow buffering hole to absorb material expansion, thereby preventing distortion
Data Source
AI summary
Provided are a method for manufacturing bottomed cans and an intermediate material for manufacturing bottomed cans capable of obtaining high quality bottomed cans with high accuracy in positioning and suppression of distortion and warpage while making a desired portion of a blank thinner, and reducing an amount of scrap to be discarded. A method for manufacturing multiple bottomed cans from a metal raw plate includes a coining step of coining at least part of an area to be blank that becomes a blank in the raw plate, after the coining step, a forming step of punching a blank from the raw plate and drawing the obtained blank into a bottomed can shape, and before the coining step, a buffering hole forming step of piercing a material flow buffering hole between the areas to be blank in the raw plate.