Hexagonal Blank Drawing with Grooved Die for Height Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing cylindrical containers from metal sheets with exposed surfaces faces challenges in suppressing height variations due to corner parts, leading to uneven container heights and reduced productivity.
Innovation Solution
Using a die and blank holder with groove-formed areas corresponding to the sides of hexagonally-shaped blanks during the drawing process, which slows down the withdrawal speed of the blank's sides relative to its corners, effectively preventing height variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hexagonally-shaped blanks are used to reduce scrap portions and improve yield rate, then productivity is improved, but portions (earings) higher in container height than other portions occur due to corner parts effect
Solution Approach 1:
The die surface is designed with differentiated local properties: smooth areas corresponding to corner parts of the hexagonal blank and groove-formed areas corresponding to side parts. This local quality differentiation allows corner parts to be drawn at different speeds, preventing the formation of high portions while maintaining the productivity benefits of hexagonal blanks.
Solution Approach 2:
The invention changes the surface parameter of the die by introducing groove-formed areas with specific geometrical features (grooves extending in the drawing direction). This parameter change modifies the friction and drawing characteristics at different locations, enabling control over the drawing speed of side parts versus corner parts to eliminate height variations.
2Manufacturing precision
If groove-formed areas are added to the die or blank holder to suppress height variations, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The die surface is segmented into distinct functional zones: smooth areas for corner parts and groove-formed areas for side parts. This segmentation allows each zone to perform its specific function independently, achieving height uniformity through localized control rather than complex overall design.
Solution Approach 2:
Instead of trying to make all parts of the blank draw at the same speed, the invention inverts the approach by intentionally creating different drawing conditions at different locations. The groove-formed areas create controlled friction differences that result in slower drawing of side parts, compensating for the corner part effect and achieving uniform height.
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 method enhances productivity by minimizing height variations and improving yield rates in cylindrical container manufacturing, especially when using metal sheets without a resin layer.
Implementation Method 1
the groove-formed area is formed with a plurality of grooves along the circumferential direction... slows down the withdrawal speed of the blank's sides relative to its corners
Data Source
AI summary
There is provided a method of manufacturing a cylindrical container using a metal sheet on at least one surface of which the metal is exposed. The method includes: obtaining a blank having a hexagonal shape from the metal sheet; and processing the blank into a cylindrical shape by pressing a central part of the blank with a punch in a state in which a peripheral part of the blank is clamped between a die for drawing process and a blank holder. The method is characterized by the following features. At least one of the die for drawing process and the blank holder has a groove-formed area at a portion of a surface thereof. The portion corresponds to a side of the blank. The groove-formed area is formed with a plurality of grooves along the circumferential direction. The blank is processed into the cylindrical shape by clamping the peripheral part of the blank between the die for drawing process and the blank holder so that the surface of the blank on which the metal is exposed is in a state of facing the groove-formed area and the side of the blank is in a position that corresponds to the groove-formed area.