Simultaneous Contoured Shoulder and Neck Forming in Metallic Containers
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Solution Overview
Problem
Existing methods for forming shoulders and necks on metallic container bodies are slow, difficult to service, and result in aesthetically unpleasing, straight shoulders with excessive material wrinkling, and are inefficient in terms of cost and production rate.
Innovation Solution
A method and apparatus that simultaneously form a contoured shoulder and neck portion on metallic container bodies using rotary drawing presses with cam-actuated rams and specialized tooling, allowing for high-speed production and easy calibration, without the need for subsequent smoothing operations, and reshaping the shoulder to change the radius between the neck and shoulder portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sequential forming methods are used to form shoulder and neck portions, then the forming process can be completed, but the production rate is slow and the shoulder appearance is aesthetically unpleasing with excessive material wrinkling
Solution Approach 1:
The patent combines the forming of the shoulder portion and neck portion into a single simultaneous operation using a multi-component draw die assembly. The draw die, draw ring, and punch work together in one forming stroke to create both features, eliminating the need for separate sequential operations and thereby increasing production rate while maintaining aesthetic quality through proper tooling design
Solution Approach 2:
The patent employs draw die faces with curved or arcuate shapes rather than linear flat faces to form contoured, rounded shoulders. This curvature in the tooling geometry directly produces the aesthetically pleasing rounded shoulder appearance while simultaneously forming the neck portion, resolving the contradiction between production speed and aesthetic quality
2Manufacturing precision
If traditional linear flat-faced tools are used for forming, then the forming operation is simple, but the resulting shoulder is straight and aesthetically unpleasing
Solution Approach 1:
The draw die is designed with curved or arcuate face geometry instead of linear flat surfaces. This curvature in the tooling directly imparts the desired contoured, rounded shoulder shape to the formed workpiece, achieving aesthetic quality while the integrated design keeps the overall tooling complexity manageable
Solution Approach 2:
The draw die assembly is segmented into multiple functional components (draw die, draw ring, punch) that work together in coordination. This segmentation allows each component to be optimized for its specific function while maintaining a relatively simple overall structure that can be serviced and calibrated easily
3Ease of repair
If multiple successive operations are used to form shoulder and neck portions, then the forming can be completed, but the process is difficult to service and calibrate
Solution Approach 1:
By merging the shoulder forming and neck portion forming into a single simultaneous operation using one integrated draw die assembly, the number of tooling changes and calibration steps is reduced. The unified tooling system requires servicing and calibration as one unit rather than multiple separate operations, improving ease of repair while maintaining high production rate
Solution Approach 2:
The draw die assembly serves multiple functions simultaneously - forming the shoulder portion, forming the neck portion, and controlling material flow all in one operation. This multi-functionality reduces the number of specialized tools needed and simplifies the overall tooling system, making it easier to service and calibrate while achieving high productivity
4Ease of manufacture
If traditional forming methods are used, then the process is established, but excessive material wrinkling occurs and subsequent smoothing operations are required
Solution Approach 1:
The simultaneous forming of shoulder and neck portions in one operation allows for coordinated control of material flow and deformation. The integrated tooling system manages material displacement more effectively, reducing excessive wrinkling and eliminating the need for subsequent smoothing operations, thereby improving both process efficiency and surface quality
Solution Approach 2:
The patent modifies forming parameters including the geometry of the draw die face (curved vs. flat), the configuration of the draw ring, and the positioning of the punch to optimize material flow during forming. These parameter changes result in more uniform deformation and reduced material wrinkling, achieving high surface quality without additional smoothing steps
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
Enables the cost-effective and efficient formation of contoured shoulders and necks at rates exceeding 200 containers per minute, with improved appearance and reduced material wrinkling, and allows for easier maintenance and calibration of tooling.
Implementation Method 1
The force from the punch deforms the metal slug around an outer diameter of the punch and the inner diameter of the confining die
Implementation Method 2
perform at least one forming operation with the punch, the draw die, and the draw ring on the closed end of the metallic container body to progressively form an arcuate shaped shoulder portion and a neck portion
Data Source
AI summary
An apparatus and method of simultaneously forming a contoured shoulder and neck portion on a closed end a metallic container are provided. More specifically, an apparatus and methods of forming a contoured shoulder and neck portion on a closed end of a metallic two-piece container are disclosed.