Variable-Radius Can Tooling for Uniform Flange Width
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Solution Overview
Problem
Conventional metal container manufacturing methods result in uneven distribution of metal at the cup top and flange width, leading to wastage of material and increased production costs due to the need for trimming to achieve even surfaces.
Innovation Solution
The use of tooling stations with blank and draw punches and draw-redraw dies featuring curved edges with varying radii of curvature to control the height and flange width, allowing for more even distribution of metal during the forming process, reducing the amount of metal needed and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional blank and draw punches with uniform radius edges are used, then the manufacturing process is simple, but the metal distribution at the cup top and flange width becomes uneven
Solution Approach 1:
The patent applies local quality by varying the radius of curvature at different locations along the curved edge of the blank and draw punch. Specifically, the radius is changed in discrete steps (e.g., R1, R2, R3 at different angular positions) rather than being uniform throughout, allowing different sections of the punch to impart different metal flow characteristics to achieve uniform metal distribution at the cup top and controlled flange width.
Solution Approach 2:
The patent implements dynamics by making the radius of curvature variable along the curved edge of the punch rather than static and uniform. This dynamic variation in geometry allows the tooling to adaptively control metal flow during the drawing process, enabling precise control over cup top uniformity and flange width while maintaining a relatively simple overall tooling design.
2Manufacturing precision
If conventional draw-redraw dies with uniform radius edges are used, then the tooling design is simple, but the flange width varies around the circumference
Solution Approach 1:
The patent applies local quality to the draw-redraw die by varying the radius of curvature at different angular positions along its curved edge. This localized variation in radius (e.g., R4, R5, R6 at different positions) allows each section of the die to control metal flow differently during redrawing, achieving consistent flange width around the entire circumference of the can.
3Loss of substance
If conventional tooling is used, then production costs are lower initially, but material wastage increases due to trimming requirements
Solution Approach 1:
The patent applies preliminary action by designing the blank and draw punch and draw-redraw die with pre-calculated variable radius profiles that anticipate and prevent metal distribution problems before they occur. This preliminary design consideration ensures that metal flows uniformly during drawing and redrawing, eliminating the need for subsequent trimming operations and reducing material wastage.
4Manufacturing precision
If variable radius curved edges are used in tooling, then metal distribution uniformity improves, but the tooling manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the curved edge of the blank and draw punch into discrete sections with different radius values (R1, R2, R3, etc. at specific angular intervals). This segmented approach to variable radius design simplifies the fabrication process compared to a continuously varying radius, as each segment can be manufactured independently and then assembled or machined in place, reducing overall tooling fabrication complexity while maintaining cup top uniformity.
Data Source
AI summary
Embodiments provide a tooling station for forming containers that includes a blank and draw punch configured to blank off a portion of stock from a stock element and draw the portion of stock to form a cup. The blank and draw punch includes a blank and draw punch curved edge disposed between a blank and draw punch inner circumferential wall and a blank and draw punch proximal surface. The blank and draw punch curved edge has a radius of curvature that varies along its circumference. The tooling station also includes a draw-redraw die configured to redraw the cup to form a can having a flange. The draw redraw die includes a draw-redraw die curved edge disposed between a draw-redraw die inner circumferential wall and a draw-redraw die proximal surface. The draw-redraw die curved edge has a radius of curvature that varies along its circumference.