Metal Can Body Forming With Zigzag Tube Cuts for Zero Scrap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing methods for metal containers, such as beer and food cans, result in significant leftover scrap material due to the process of punching circular discs from rectangular sheets, leading to increased costs for can manufacturers.
Innovation Solution
A zero-scrap method involving cutting metal sheets into strips, winding them into cylindrical tubes, and using a zigzagged pattern to create can bodies with a planar edge and triangular formations, which are then folded and friction stir welded to form a sealed base, reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular discs are punched from rectangular metal sheets, then can bodies can be produced, but significant scrap material is generated at the edges and between adjacent discs
Solution Approach 1:
The rectangular metal sheet is divided into multiple strips running the length of the sheet, with each strip then formed into a cylindrical tube. This segmentation allows the entire sheet to be utilized efficiently, converting what would have been scrap edge material into useful structural components of the can body.
Solution Approach 2:
Instead of punching circular discs from rectangular sheets (traditional approach), the invention inverts the process by first creating cylindrical tubes from rectangular strips and then cutting the tubes to form can bodies. This fundamental reversal of the manufacturing sequence eliminates scrap generation at the source.
2Productivity
If rectangular metal sheets are used to produce multiple can bodies, then mass production is enabled, but leftover material remains at the edges and between discs
Solution Approach 1:
The metal sheet is segmented into multiple parallel strips that run the full length of the sheet. Each strip is then formed into a cylindrical tube containing multiple can body sections. This segmentation strategy maintains high productivity by processing entire sheets efficiently while eliminating the material waste associated with circular punching methods.
Solution Approach 2:
The invention transitions from a two-dimensional disc punching approach to a three-dimensional tubular formation approach. By forming cylindrical tubes from rectangular strips and then cutting along zigzag paths, the method utilizes the full dimensional capacity of the metal sheet, converting edge waste into useful structural elements of the can body.
3Ease of manufacture
If circular discs are punched from metal sheets, then can bodies can be formed, but the process is inefficient due to material waste
Solution Approach 1:
The invention inverts the traditional manufacturing sequence by first forming cylindrical tubes from rectangular metal strips and then cutting the tubes to create can bodies. This reversal eliminates the need for circular punching operations, thereby eliminating the associated material waste and improving manufacturing efficiency throughout the entire production process.
Solution Approach 2:
The rectangular metal sheet is pre-formed into cylindrical tubes before being cut into individual can bodies. This preliminary forming action creates a structure that is inherently more efficient to manufacture from, as it eliminates the need for subsequent material removal operations and maximizes the utilization of the original metal sheet.
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 significantly reduces material waste by efficiently forming can bodies with a sealed base, enhancing manufacturing efficiency and reducing costs for can manufacturers.
Implementation Method 1
A friction stir welding assembly that includes a stirring tool with a circular welding surface having a greater circumference than the flattened can end then stir welds the entire flattened end of the can body at one time in order to seal all seams of the flattened can end
Data Source
AI summary
A zero-scrap method and associating tooling for manufacturing can bodies is provided. A metal sheet is shorn into strips, and each strip is wound to form a cylindrical tube. Each tube is cut into two or more can bodies using a zigzagged pattern, such that each can body has one planar edge and one zigzagged edge with triangular formations. Each can body is mounted on a mounting base for support while steps are performed to form the zigzagged edge into the can body base. A folding die folds the triangular formations until their apexes all coincide with one another and with the central axis of the can body. A flattening die then flattens the folded formation into a flat end of the can body. A friction stir welding assembly then stir welds the entire flat end of the can body at one time in order to seal all seams.