Deep Drawing Friction Control with Electro-Activated Lubrication
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Solution Overview
Problem
In high-rate manufacturing processes for metal products like aluminum beverage containers, excessive friction between the metal and forming equipment leads to damaged products, equipment jamming, and costly downtime, with existing lubricants either inadequate for lubrication or difficult to remove, and current methods do not effectively control friction dynamics during forming and ejection.
Innovation Solution
Applying an electric current through lubricants on the punch and die surfaces to control friction coefficients, combined with ultrasonic vibrations to adjust frictional forces, allowing for optimized forming and ejection of metal products by varying the friction levels between the metal and forming equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lubricants are used to reduce friction during forming, then lubrication is provided, but the lubricant is difficult to remove or leaves residue on the formed metal surface
Solution Approach 1:
The patent applies electric current to change the physical-chemical parameters of the lubricant, transforming it from a conventional state to an activated state with enhanced lubrication properties and improved removability. This parameter change allows the lubricant to provide sufficient lubrication during forming while being easier to remove after the process.
Solution Approach 2:
The patent replaces conventional mechanical lubrication methods with an electro-activated lubrication system. Instead of relying solely on the inherent properties of the lubricant, electric current is used to activate and enhance the lubricant's performance, substituting a purely mechanical approach with an electro-mechanical one.
2Productivity
If high rate manufacturing processes are used to increase productivity, then production speed is improved, but damaged metal products can jam the forming equipment resulting in costly downtime
Solution Approach 1:
The patent implements a feedback mechanism where electric current is applied to the lubricant based on the forming process conditions. This feedback control activates the lubricant at critical moments to prevent damage, ensuring that high-rate manufacturing does not compromise equipment reliability or cause jamming.
Solution Approach 2:
The patent applies electric current to the lubricant in advance of or during the forming operation to pre-activate the lubrication properties. This preliminary action ensures that adequate lubrication is present before metal-to-metal contact occurs, preventing damage even at high manufacturing rates.
3Ease of manufacture
If existing ironing dies are used, then forming capability is provided, but excessive friction causes cup walls to tear or weaken
Solution Approach 1:
The patent replaces conventional passive mechanical forming with an electro-activated forming process. Electric current is applied to the lubricant to enhance its lubrication properties during ironing, reducing friction between the cup walls and die to prevent tearing or weakening while maintaining forming capability.
Solution Approach 2:
The patent changes the physical-chemical parameters of the lubricant through electric current activation. This parameter change enhances the lubricant's film strength and reduces friction coefficient during the ironing process, protecting cup wall integrity while enabling effective forming.
4Ease of manufacture
If existing ironing dies are used, then forming capability is provided, but excessive friction dislodges metal particulate from the cup which builds up on the die
Solution Approach 1:
The patent replaces conventional mechanical ironing with an electro-activated lubrication system. By applying electric current to enhance lubrication during ironing, the process reduces metal-to-metal contact and friction, preventing dislodgement of metal particulate from the cup and subsequent buildup on the die.
Solution Approach 2:
The patent converts the potential harm of high friction and metal particulate generation into a benefit by using electric current to activate the lubricant. This transformation reduces friction to levels that prevent particulate dislodgement, turning a harmful friction-based process into a cleaner, more controlled operation.
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 reduces damage to metal products, minimizes equipment jams, and enhances manufacturing efficiency by dynamically controlling friction, ensuring reliable and precise forming operations while reducing the need for frequent die cleaning and replacement.
Implementation Method 1
applying an electric current 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
Implementation Method 2
ultrasonic vibrations to adjust frictional forces
Data Source
Figure 1A~1B
Figure 2
Figure 3
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 a base 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.