Lightweight Cemented Carbide Punch Composition for Can Forming
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Solution Overview
Problem
The can manufacturing process for metal beverage cans is demanding and requires tools with high hardness, fracture toughness, compressive strength, and stiffness, while also being resistant to wear, tear, and corrosion. Existing punches are heavy, leading to high energy consumption and tool damage due to bending effects.
Innovation Solution
A low weight cemented carbide punch composition with tungsten carbide (WC) 67-76 wt.%, titanium and niobium (Ti, Nb) as gamma phase constituents 10-17 wt.%, cobalt (Co) and chromium (Cr) 12-13 wt.%, and a balance of carbon, achieving a density range of 11.2-12.5 g/cm3, maintaining HV30 Vickers hardness of 1520-1570 and fracture toughness of 10.2-10.6 MPa√m.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional heavy cemented carbide punches are used, then tool strength and stiffness are sufficient, but energy consumption increases and tool alignment deteriorates due to bending effects
Solution Approach 1:
The patent changes the material composition parameters by incorporating tungsten carbide grains sized 0.4-0.8 μm, gamma phase constituents (Ti, Nb, Ta) totaling 15-25 wt.%, and Co binder 10-14 wt.%, achieving a density of 11.2-12.5 g/cm3. This parameter optimization reduces punch weight while maintaining mechanical properties sufficient for can manufacturing, thereby reducing energy consumption without compromising tool performance
Solution Approach 2:
The patent employs a composite cemented carbide material consisting of WC hard phase, gamma phase (TiC, NbC, TaC), and Co binder phase. This composite structure achieves an optimal balance between weight reduction and mechanical strength, allowing the punch to be lighter while maintaining adequate stiffness and toughness for the drawing and ironing operations
2Use of energy by moving object
If punch weight is reduced, then energy consumption decreases, but tool strength and resistance to wear and tear may deteriorate
Solution Approach 1:
The patent optimizes composition parameters including WC content (67-76 wt.%), gamma phase (10-17 wt.%), and Co binder (12-13 wt.%) to achieve a density of 11.2-12.5 g/cm3. This parameter control ensures adequate hardness (HV30: 1520-1570) and fracture toughness (10.2-10.6 MPa√m), maintaining wear resistance while reducing weight for lower energy consumption
Solution Approach 2:
The composite structure with WC providing hardness, gamma phase enhancing toughness, and Co binder ensuring ductility creates a synergistic material that resists wear and tear. The specific composition ratios ensure the tool maintains reliability despite reduced weight, preventing premature failure during continuous can manufacturing operations
3Object-generated harmful factors
If punch weight is reduced, then bending effects on the ram decrease, but maintaining adequate fracture toughness becomes more difficult
Solution Approach 1:
The patent adjusts the gamma phase constituent content (Ti, Nb, Ta) to 15-25 wt.%, which significantly enhances fracture toughness. This parameter change allows the lighter punch to maintain adequate strength and resistance to bending effects, ensuring the ram experiences reduced harmful forces without compromising tool integrity
Solution Approach 2:
The gamma phase (TiC, NbC, TaC) acts as a toughening agent in the composite structure, absorbing energy and preventing crack propagation. This composite design enables the punch to withstand bending forces with reduced weight, protecting the ram from damage while maintaining structural integrity
4Weight of moving object
If gamma phase constituents (Ti, Nb) are increased to reduce density, then punch weight decreases, but hardness may deteriorate
Solution Approach 1:
The patent precisely controls the gamma phase content at 10-17 wt.% and WC content at 67-76 wt.%, balancing density reduction with hardness maintenance. This parameter optimization achieves density of 11.2-12.5 g/cm3 while maintaining adequate HV30 hardness (1520-1570), preventing excessive softening that would occur with higher gamma phase content
Solution Approach 2:
The composite structure leverages the hardness of WC grains and the toughness of gamma phase in optimized proportions. The Co binder phase (12-13 wt.%) provides additional support for maintaining structural integrity. This balanced composite design reduces weight through gamma phase incorporation while WC content ensures sufficient hardness for can manufacturing operations
Data Source
AI summary
Provided are low weight punches for manufacturing metal beverage cans having a sintered cemented carbide punch composition including a carbide hard phase having tungsten carbide (WC) in an amount of from about 67 wt. % to about 76 wt. % based on a total weight of the sintered cemented carbide punch composition, and a gamma phase having at least titanium (Ti) and niobium (Nb) as gamma phase constituents in an amount of from about 10 wt. % to about 17 wt. % based on a total weight of the sintered cemented carbide punch composition. The sintered cemented carbide punch composition further includes a binder phase including at least cobalt (Co) and chromium (Cr) in an amount of from about 12 wt. % to about 13 wt. % based on a total weight of the sintered cemented carbide punch composition, and a balance of carbon. Methods for producing such low weight cemented carbide punches are further disclosed.