Deep Drawing Friction Control Using Electro-Lubrication and Ultrasound

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

High rate manufacturing processes for metal products, such as aluminum beverage containers, face issues with excessive friction during forming, leading to damaged products and equipment jams, which result in costly downtime and residue buildup on dies.

Innovation Solution

Applying an electric current through lubricants to control friction coefficients between metal products and forming equipment, and using ultrasonic vibrations to reduce friction and prevent metal buildup on dies during the forming process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional lubricants are used during deep drawing, then friction is reduced to some extent, but excessive friction remains causing cup wall tearing and equipment damage

Engineering Contradiction:

Improveforming process reliabilityVSAvoidfriction between cup sidewalls and die

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies electric current to change the physical state of the lubricant, transforming it from a conventional static lubricant to an electrically activated lubricant with modified friction properties. This parameter change (adding electrical field) allows dynamic control of friction coefficients during different forming stages

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional mechanical lubrication systems with an electro-lubrication system where electric current serves as the controlling mechanism. This substitution enables precise control of friction through electrical parameters rather than relying solely on mechanical lubricant application

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If high friction is present during forming, then material flow control is improved, but product damage and equipment jams occur

Engineering Contradiction:

Improvematerial flow controlVSAvoidproduct damage and equipment jams

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent introduces dynamic control of friction coefficients through electric current application. The friction characteristics are no longer static but can be adjusted in real-time during the forming process, allowing optimization of material flow while preventing excessive friction-induced damage

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates feedback mechanisms where the forming process conditions are monitored and electric current is adjusted accordingly to maintain optimal friction levels. This closed-loop control prevents both insufficient lubrication (causing tearing) and excessive lubrication (causing slippage and jams)

Inventive Principle:

Principle #23Feedback

3Reliability

If oil-based lubricants are used to reduce friction, then lubrication performance improves, but residue buildup on die surfaces occurs

Engineering Contradiction:

Improvelubrication performanceVSAvoidresidue buildup on die

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent introduces electric current as an intermediary that activates the lubricant's performance without requiring heavy oil-based formulations. The electrical field enhances the lubricant's effectiveness, allowing for reduced lubricant quantity and improved ease of removal from die surfaces

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By applying electric current, the patent changes the physical and chemical parameters of the lubricant during operation. This activation allows the lubricant to provide superior lubrication with lower viscosity formulations that leave minimal residue on die surfaces

Inventive Principle:

Principle #35Parameter changes

4Productivity

If high rate manufacturing is implemented to increase productivity, then output increases, but forming failures and downtime increase

Engineering Contradiction:

Improvemanufacturing rateVSAvoidforming process stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent ensures continuous successful forming operations by preventing forming failures through controlled friction management. The electrically activated lubrication system maintains consistent performance throughout high-rate production, eliminating interruptions due to product damage or equipment jams

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system uses real-time feedback to adjust electric current parameters during high-rate manufacturing, ensuring that friction remains within optimal ranges even under increased production speeds. This prevents forming failures that would otherwise occur at high manufacturing rates

Inventive Principle:

Principle #23Feedback

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

Optimizes the forming process by minimizing damage to metal products and equipment, reducing downtime, and preventing residue buildup, thereby improving the reliability and efficiency of metal forming operations.

Implementation Method 1

an electric current may be applied to or through a lubricant used during a stamping or punching process to modify a friction coefficient between the metal product and the stamping surface

Methodology Applied

Scientific EffectElectric current through lubricant: Conduction (electrical)

Implementation Method 2

ultrasonic vibrations can be applied to parts of the stamping or drawing equipment, or the metal product, to modify frictional forces

Methodology Applied

Scientific EffectUltrasonic vibrations: Ultrasonic Vibration

Data Source

PatentUS12179248B2Devices and methods configured to manipulate friction between a working piece and a deep drawing tool in a deep drawing process

Publication Date: 2024.12.31 NOVELIS INC(US)

AI summary

The invention relates to a system for making a metal product, comprising—a lubrication source (225) for applying a first lubricant (235) on a punch side of a sheet metal blank (205);—a controllable current source (250) for applying different amounts of current; and—a punch (215) and a die (220) for drawing the sheet metal blank (205) into a metal product, wherein the controllable current source (250) is electrically coupled to one or more of the punch (215), the die (220), or a contact point for applying current through the first lubricant (235) while the sheet metal blank (205) is drawn by the punch (215) and the die (220) into the metal product and while the metal product is being ejected from the punch (215). The application further relates to a method for making a metal product with a such system. The invention relates also to a container manufacturing system (700), comprising—a cylindrical ram (720) comprising a ram body (722) and a ram nose on a distal end of the ram body (722), the ram nose engageable with abase of a container preform;—a die (730) comprising an opening concentrically aligned with the cylindrical ram (720), the opening sized and shaped for receiving the container preform in response to the ram nose engaging with the base of the container preform and the cylindrical ram (720) driving the container preform through the die opening; and—an ultrasonic device (740) coupled with the die (730), wherein the ultrasonic device causes the die (730) to vibrate while the cylindrical ram (720) drives the container preform through the die opening. The application further relates to a method for forming an aluminium container with such system and a die (730) for forming an aluminium container.