Variable-Radius Can Forming Tools for Uniform Flange Width
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Solution Overview
Problem
Conventional metal container manufacturing methods, such as the draw-redraw and drawn and ironed processes, result in uneven metal distribution at the cup top and flange width, leading to waste and increased production costs due to the need for trimming excess metal to achieve even surfaces.
Innovation Solution
A tooling station system featuring a blank and draw punch with a curved edge of varying radius curvature and a draw-redraw die with a similarly varying curved edge, allowing for more even metal distribution by controlling the cup height and flange width through the use of tangent points during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional draw-redraw or drawn and ironed processes are used, then container formation is achieved, but uneven metal distribution occurs at the cup top and flange width, requiring trimming operations that increase production costs and time
Solution Approach 1:
The blank and draw punch features a curved edge with a radius of curvature that varies along its circumference, creating different local forming conditions around the cup perimeter. This non-uniform geometry allows precise control over metal flow distribution, ensuring even metal distribution at the cup top and flange width without requiring subsequent trimming operations
Solution Approach 2:
The invention changes the geometric parameter of the punch curved edge from a constant radius to a variable radius along the circumference. This parameter variation enables different sections of the metal blank to be drawn with different degrees of curvature control, achieving uniform metal distribution and eliminating the need for trimming while maintaining high production efficiency
2Loss of substance
If conventional tools with constant radius curved edges are used, then the forming process is simple, but excessive metal is required and waste increases due to uneven distribution
Solution Approach 1:
The blank and draw punch features a curved edge with a radius of curvature that varies along its circumference, creating different local forming conditions around the cup perimeter. This non-uniform geometry allows precise control over metal flow distribution, ensuring even metal distribution at the cup top and flange width without requiring subsequent trimming operations
Solution Approach 2:
The invention changes the geometric parameter of the punch curved edge from a constant radius to a variable radius along the circumference. This parameter variation enables different sections of the metal blank to be drawn with different degrees of curvature control, achieving uniform metal distribution and eliminating the need for trimming while maintaining high production efficiency
Data Source
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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.