Shell Forming Biasing Member and Die Core Control
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Solution Overview
Problem
Existing shell forming technologies face issues with excessive heat generation and strain hardening in the inner pressure sleeve, leading to tolerance issues and potential deformation of the can end under pressure, and lack precision and stability in the die core's control over the chuck wall formation.
Innovation Solution
The apparatus employs a biasing member to selectively control the movement of the inner pressure sleeve and uses a die core with an outer diameter equal to or greater than the punch core, ensuring the portion adjacent to the die core is in contact with the die core ring, which provides greater control, precision, and stability during shell formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the inner pressure sleeve is mounted around a punch core or supported on a column of gas or piston, then the shell forming process can proceed, but excessive heat generation occurs in the inner pressure sleeve leading to thermal expansion and tolerance issues
Solution Approach 1:
The patent removes the inner pressure sleeve from direct contact with the punch core and eliminates the column of gas or piston support system. Instead, the inner pressure sleeve is directly mounted on the punch core with improved clearance specifications, extracting the heat generation problem from the system by eliminating the intermediate supporting elements that caused excessive heat buildup.
Solution Approach 2:
The patent specifies precise clearance parameters between the inner pressure sleeve and punch core (0.001 to 0.005 inches) and controls the outer diameter of the punch core relative to the die core (equal to or greater than). These parameter changes optimize the fit to reduce friction and heat generation while maintaining forming capability.
2Productivity
If the inner pressure sleeve is mounted around a punch core or supported on a column of gas or piston, then the shell forming process can proceed, but excessive strain hardening occurs in the chuck wall area causing cracking or deformation under pressure
Solution Approach 1:
The patent introduces a die core ring as an intermediary element between the die core and the inner pressure sleeve. The die core ring has a tapered surface that contacts the inner pressure sleeve during forming, mediating the force application to distribute stress more evenly and prevent excessive strain hardening in the chuck wall area while maintaining forming effectiveness.
Solution Approach 2:
The patent specifies that the outer diameter of the punch core should be equal to or greater than the outer diameter of the die core, and defines the tapered surface geometry of the die core ring. These parameter changes optimize the force distribution during forming to reduce strain hardening while maintaining structural integrity.
3Productivity
If the die core outer diameter is less than the punch core outer diameter, then the forming process can proceed, but the portion adjacent to the die core surface lacks contact with the die core ring resulting in reduced control and precision
Solution Approach 1:
The patent introduces a die core ring as an intermediary element that provides the necessary contact surface. The die core ring's tapered surface contacts the inner pressure sleeve, ensuring precise control and stability during chuck wall formation. This intermediary element bridges the gap between the die core and the forming process requirements.
Solution Approach 2:
Instead of making the die core smaller than the punch core, the patent inverts the approach by making the die core outer diameter equal to or greater than the punch core outer diameter. This inversion ensures proper contact and control during the forming process, improving manufacturing precision.
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 effectively reduces excessive heat generation and strain hardening, ensuring the formed shells meet tolerance requirements and can sustain high internal pressures without deformation, while providing precise control over the chuck wall formation.
Implementation Method 1
a biasing member that selectively biases and controls movement of the inner pressure sleeve
Data Source
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AI summary
An apparatus and method for forming a shell with a central panel and a chuck wall is provided. The apparatus and method employ the use of a biasing member to selectively bias and control movement of the inner pressure sleeve and a die core having an outer diameter equal to or greater than the outer diameter of the punch core. The apparatus and method can also be employed in a single action press or a double action press.