Cemented Carbide Punch Wear Resistance and Density Trade-off
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Solution Overview
Problem
Existing cemented carbide tools used in manufacturing metal beverage cans face challenges with low wear resistance, toughness, and magnetic properties, leading to reduced service life and increased maintenance due to tight tolerances and corrosive environments.
Innovation Solution
A cemented carbide punch with a hard phase comprising WC and a binder phase of Co+Ni, optimized with TiC and Cr+Mo additions, providing improved wear resistance, toughness, and magnetic permeability, while maintaining a high WC content to reduce bending moments and enhance alignment and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the WC content is increased to improve wear resistance and reduce bending moments, then the service life and alignment are improved, but the density increases leading to higher energy consumption
Solution Approach 1:
The patent optimizes the WC content parameter within a specific range (60-80 wt%) to achieve the desired balance between wear resistance, bending moment reduction, and acceptable density. This parameter optimization allows the material to provide sufficient service life while limiting excessive weight increase.
Solution Approach 2:
The patent uses a composite cemented carbide material consisting of WC hard phase combined with a Co-Ni binder phase. This composite structure provides both the wear resistance needed for extended service life and the opportunity to control density through binder phase composition, thereby managing the weight-punch weight trade-off.
2Reliability
If Co content is increased to improve magnetic permeability, then the magnetic properties are improved, but the corrosion resistance deteriorates
Solution Approach 1:
The patent optimizes the Co content within a specific range (10-20 wt%) to achieve adequate magnetic permeability while limiting excessive corrosion susceptibility. This parameter control allows the material to maintain reliable magnetic properties for can making applications without sacrificing too much corrosion resistance in the corrosive manufacturing environment.
Solution Approach 2:
The patent employs a composite binder phase consisting of Co combined with Ni (in a weight ratio of 0.3-2.5). This composite binder system provides both the magnetic permeability needed for reliable operation and improved corrosion resistance compared to pure Co, thereby resolving the trade-off between magnetic properties and corrosion resistance.
3Strength
If the binder phase content is increased to improve toughness, then the toughness is improved, but the wear resistance deteriorates
Solution Approach 1:
The patent optimizes the total binder phase content (Co+Ni) within a specific range (10-20 wt%) to achieve adequate toughness while maintaining sufficient wear resistance. This parameter optimization ensures the punch has enough toughness to withstand impact loads during can making while retaining adequate wear resistance for extended service life.
Solution Approach 2:
The patent uses a composite binder phase of Co-Ni that provides both toughness and wear resistance properties. The specific composition and ratio of Co to Ni in the binder phase are optimized to achieve a balance where the material has sufficient toughness to prevent fracture while maintaining adequate wear resistance for reliable operation over 10 million cans or more.
Data Source
Figure 1
AI summary
The present invention relates to a punch for manufacturing of metal beverage cans of a cemented carbide comprising a hard phase comprising WC and a binder phase the cemented carbide composition comprises, in wt-%, from 50 to less than 70 WC, from 15 to 30 TiC, and from 12 to 20 Co+Ni.