Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D37/00—Tools as parts of machines covered by this subclass
  • B21D37/20—Making tools by operations not covered by a single other subclass
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
  • B21D22/20—Deep-drawing
  • B21D22/28—Deep-drawing of cylindrical articles using consecutive dies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D41/00—Application of procedures in order to alter the diameter of tube ends
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
  • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
  • B24C1/10—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D7/00—Modifying the physical properties of iron or steel by deformation
  • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
  • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
  • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like

Definitions

• substantially identically shaped metal beverage containers are produced massively and relatively economically.
• dies have been used to neck and shape the containers. Often several operations are required using several different necking dies to narrow each metal container a desired amount.
• An expansion die for manufacturing metal containers comprises a work surface configured to expand a diameter of a metal container having a closed bottom.
• the work surface comprises a progressively expanding portion and a land.
• the outer diameter of the land is a maximum diameter of the die.
• a portion of the work surface of the expansion die has a surface finish having a maximum ratio of the closed void area in the range of about one of 1%-
• At least a portion of the land of the expansion die has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10% ⁇ 26%, 10%-20%, 10%- 15% and 12%-15%.
• at least a section of the progressively expanding portion has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%-15% and 12%-15%.
• the maximum ratio of the closed void area is the closed void area total area measured (times 100 for percentage).
• a portion of the work surface of the expansion die including a portion of the progressively expanding portion and/or the land, has a normalized closed void volume in the range of about one of 1-2000 mm3/m2, 9-1674 mm3/m2, 33-388 mm3/m2, 100-300 mm3/m2, 100-250 mm3/m2, 125-250 mm3/m2, 150-250 inm3/m2 and 155- 231 mm3/m2.
• the normalized closed void volume is the closed void area times the depth of the area and quantifies the amount of lubricant that is able to be trapped in the valleys of the surface.
• a progressively expanding portion has dimensions and a geometry that when inserted into the open end of a container works the container's sidewall to radially expand the container's diameter in a progressive manner as the container travels along the work surface.
• a land is the portion of the working surface of an expansion die having the largest outer diameter that contacts a section of a container while the die is expanding the container. It is possible for a die to have multiple sections, each section having a land, each land having a different outer diameter. The land having the smaller outer diameter travels farther into the container than the land having the larger outer diameter.
• An example of a die having multiple lands can be seen in Figure 1.
• an initial portion of the work surface of the expansion die has geometry for forming a transition in a container from an original diameter portion to an expanded diameter portion. In some embodiments, the transition is stepped or gradual.
• the expansion die has an undercut portion, wherein the land is between the progressively expanding portion and the undercut portion.
• the land portion has dimensions and a geometry for setting the final diameter of the container being formed by that expansion die.
• the length of the land of the expansion die may be 0.12" or more.
• the length of the land of the expansion die may be .010", .020", 0.04", 0.05, 0.08 or 0.10 or more or less.
• the length of the land of the expansion die is in the range between line contact of a continuous radius to 0.01".
• an undercut portion follows the land portion.
• the transition from the land portion to the undercut portion is blended.
• At least a portion of the undercut portion has surface roughness average (Ra) of about 8 ⁇ in. to about 32 ⁇ in.
• the progressively expanding portion has a surface roughness average (Ra) of about 2 ⁇ in. to about 6 ⁇ in.
• at least a portion of the land of the expansion die has surface roughness average (Ra) of about 8 ⁇ in. to about 32 ⁇ in.
• At least a portion of the work surface of the expansion die, including at least a portion of the land, the progressively expanding portion and/or the undercut portion has a surface roughness average measured in 3 dimensions (Sa) in the range of about 1-50 ⁇ in, 1-48 ⁇ in, 7-43 ⁇ in, 20-50 ⁇ in, 20-45 ⁇ in, 25-45 ⁇ in, 30-45 ⁇ in, 20-40 ⁇ in, 30-40 ⁇ in.
• An undercut portion comprises an undercut surface having an outer diameter. The outer diameter of the undercut surface is at least approximately 0.01 inches smaller than the outer diameter of the land portion and no less than a minimum diameter so as to reduce but not eliminate frictional contact between the undercut surface and the metal container.
• the outer diameter of the undercut surface is dimensioned to minimize collapse, fracture, wrinkle and all other physical defects, which may occur during expansion.
• the diameter of the undercut surface is about 0.007S to about 0.035 inches less than the outer diameter of the land portion. In other embodiments, the diameter of the undercut surface is about 0.01, 0.02 or 0.03 inches less than the outer diameter of the land portion.
• the work surface of the expansion die is dimensioned so that when inserted into the metal container the entire land and at least a portion of the undercut portion enter the metal container and the land causes the diameter of at least a portion of the container to expand.
• a die for narrowing a diameter of a metal container comprises a work surface configured to narrow a diameter of a metal container having a closed bottom.
• the work surface comprises: a neck radius portion, a shoulder radius portion and a land.
• the inner diameter of the land is a minimum diameter of the die.
• At least a portion of the work surface of the die for narrowing a diameter of a metal container has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%- 15% and 12%- 15%.
• at least a portion of the land has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%- 15% and 12%- 15%.
• At least a section of the neck radius portion has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%- 15% and 12%-15%.
• at least a section of the shoulder radius portion has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%- 15% and 12%- 15%.
• a portion of the work surface including a portion of the neck radius portion, the shoulder radius portion and/or the land, has a normalized closed void volume in the range of about one of 1- 2000 mm3/m2, 9-1674 mm3/m2, 33-388 ram3/m2, 100-300 mm3/m2, 100-250 mm3/m2, 125- 250 mm3/m2, 150-250 mm3/m2 and 155-231 mm3/in2.
• a land is the portion of the working surface of an expansion die having the smallest inner diameter that contacts a section of a container. It is possible for a die to have multiple sections, wherein each section has a land, each land having a different inner diameter. The land having the larger inner diameter travels further into the container than the land having the smaller inner diameter.
• the length of the land of the die for narrowing a diameter of a metal container is between about 0.02" to about 0.08". In other embodiments, the length of the land of the die for narrowing a diameter of a metal container is about 0.03" to about 0.07'. In yet other embodiments, the length of the land of the die for narrowing a diameter of a metal container is between about 0.04" to about 0.06". In one embodiment, the length of the land of the die for narrowing a diameter of a metal container is about 0.04". In one embodiment, the length of the land of the die for narrowing a diameter of a metal container is in the range between line contact of a continuous radius to 0.01".
• a neck radius portion is a portion of the necking die that forms a radius on the container immediately adjacent to a neck or the portion of the container having its diameter narrowed by a land of the die.
• a shoulder radius portion is a portion of a necking die that forms a radius on the container being narrowed adjacent to a neck radius.
• the die for narrowing a diameter of a metal container, has a relief, wherein the land is between the neck radius portion and relief.
• the transition between the land and the relief is blended.
• at least a portion of the relief has surface roughness average (Ra) of about 8 ⁇ in. to about 32 ⁇ in.
• at least a section of the shoulder radius portion has a surface roughness average (Ra) of about 2 ⁇ in. to about 6 ⁇ in.
• at least a section of the neck radius portion has a surface roughness average (Ra) of about 2 ⁇ in. to about 6 ⁇ in.
• at least a portion of the land has surface roughness average (Ra) of about 8 ⁇ in. to about 32 ⁇ in.
• At least a portion of the work surface including at least a portion of the land, the shoulder radius portion, neck radius portion and/or the relief has a surface roughness average measured in 3 dimensions (Sa) in the range of about 1-50 ⁇ in, 1-48 ⁇ in, 7-43 ⁇ in, 20-50 ⁇ in, 20-45 ⁇ in, 25-45 ⁇ in, 30-45 ⁇ in, 20-40 ⁇ in, 30-40 ⁇ in.
• Sa surface roughness average measured in 3 dimensions
• the dimensions of the relief are provided to reduce frictional contact with the metal container and the necking die, once the metal container has been necked through the land and knockout. Therefore, in some embodiments, the relief in conjunction with the Ra of the necking surface contributes to the reduction of frictional contact between the necking die wall and the metal container being necked, wherein the reduced frictional contact maintains necking performance while reducing the incidence of collapse and improving stripping of the metal container. In one embodiment, the relief extends into the necking die wall by at least 0.005 inches measured from the base of the land.
• the relief may extend along the necking direction (along the y-axis) the entire length of the top portion of the metal container that enters the necking die to reduce the frictional engagement between the metal container and the necking die wall to reduce the incidence of collapse yet maintain necking performance.
• the relief comprises a relief surface, wherein an inner diameter of the relief surface is at least about 0.01 inches greater than the inner diameter of the land portion and an inner diameter of the relief surface is no greater than a maximum diameter so as to reduce but not eliminate frictional contact between the sidewall of the metal container and the relief surface while maintaining necking performance when necking the sidewall of the metal container.
• the diameter of the relief surface is about 0.0075 to about 0.035 inches greater than the inner diameter of the land portion.
• the diameter of the relief surface is about 0.01, 0.02 or 0.03 inches greater than the inner diameter of the land portion.
• the work surface is dimensioned so that when inserted into the metal container the entire land and at least a portion of the relief travel relative to the container in an axial direction and at least a portion of the relief travels beyond a top of the container.
• an expansion die for manufacturing metal containers comprises a work surface configured to expand a diameter of a metal container having a closed bottom.
• the work surface comprises a progressively expanding portion; and a land.
• An outer diameter of the land is a maximum diameter of the die.
• the expansion die is expanding a metal container, at least a portion of the work surface has a surface having a ratio of area in contact with the metal container to area not in contact with the metal container in the range of about one of 25-99%, 30-71%, 41-71%, 40-55%, 40-52%, 35-55% and 30-60%.
• the expansion die of this paragraph has the same characteristics of the expansion die(s) described above.
• a die for manufacturing metal containers comprises a work surface configured to narrow a diameter of a metal container having a closed bottom.
• the work surface comprises: a neck radius portion, a shoulder radius portion and a land.
• An inner diameter of the land is a minimum diameter of the die.
• a method of manufacturing a die for shaping metal containers comprises: providing an expansion die for manufacturing metal containers comprising a work surface configured to expand a diameter of a metal container having a closed bottom; and peening at least a portion of the work surface.
• the work surface comprises a progressively expanding portion and a land.
• An outer diameter of the land is a maximum diameter of the die.
• At least a portion of the land is peened. In some embodiments, at least a portion of the progressively expanding portion is peened.
• the work surface is peened with precision balls having a diameter in the range of about one of 1/16th in-3/32th in and l/16th in-5/32th in.
• the peened portion of the work surface has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%-15% and 12%- 15%.
• the peened portion of the work surface has a ratio of area in contact with the metal container to area not in contact with the metal container in the range of about one of 25-99%, 30-71%, 41-71%, 40-55%, 40-52%, 35-55% and 30-60%.
• the percent of area of the working surface that is peened is about one of 50-100%, 71-76%, 68-78%, 50-80%, 60-80% and 60-70%.
• air pressure used to thrust the precision balls while peening the die surface is in the range of about one of 10-30 psi, 15-20 psi, 10-20 psi and 15-30 psi.
• a method of manufacturing a die for shaping metal containers comprises: providing a die for manufacturing metal containers comprising a work surface configured to narrow a diameter of a metal container having a closed bottom; and peening at least a portion of the work surface.
• the work surface comprises: a neck radius portion, a shoulder radius portion and a land.
• An inner diameter of the land is a minimum diameter of the die.
• at least a portion of the land is peened.
• at least a portion of the shoulder radius portion is peened.
• at least a portion of the neck radius portion is peened.
• the work surface is peened with precision balls having a diameter in the range of about one of 1/16th in-3/32th in and 1/16th in- 5/32th in.
• the peened portion of the work surface has a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%- 15% and 12%-15%.
• the peened portion of the work surface has a ratio of area in contact with the metal container to area not in contact with the metal container in the range of about one of 25-99%, 30-71%, 41-71%, 40-55%, 40- 52%, 35-55% and 30-60%.
• the percent of area of the working surface that is peened is about one of 50-100%, 71-76%, 68-78%, 50-80%, 60-80% and 60-70%.
• the air pressure used to thrust the precision balls while peening the die surface is in the range of about one of 10-30 psi, 15-20 psi, 10-20 psi and 15-30 psi.
• All of the above embodiments are able to be used when narrowing or expanding a metal container without the use of lubricant
• All of the above embodiments are suitable for use on any type of metal container including drawn and ironed aluminum containers having a closed, integral bottom, aka a two-piece container.
• the metal comprising the metal container may be any metal known in the art including, but not limited to, aluminum and steel.
• the metal container may or may not have a dome.
• the metal container is a one-piece metal container having a closed bottom.
• the metal container is comprised of multiple pieces of metal seamed together.
• a surface finish having a maximum ratio of the closed void area in the range of about one of l%-30%, 4%-26%, 10%-26%, 10%-20%, 10%-15% and 12%-15% will be referred to as a "textured surface” herein.
• the open void volume and closed void volume are as characterized by WinSam (Surface Analysis Module for Windows) as described in ("Surface Characterisation in Forming Processes by Functional 3D Parameters," S. Weidel, U. Engel, Int. J. Adv. Manuf. Technol. (2007) 33: 130-136), which is incorporated herein by reference.
• the textured surface is created on the necking and expansion dies via peening with precision ball bearings to create a smooth, but dimpled, texture.
• Peening comprises thrusting precision balls with hardness greater than the die to create dimples in the tool surface.
• the design of the finished surface relies on the size and hardness of the balls, the velocity of the blast process, and the number of repeat hits against the die.
• a precision ball is a ball having a diameter that varies by no more than about 1%
• a tool surface that is smooth, but not flat, is able to reduce friction without excessive debris generation or tool wear.
• the reduced friction is due to reduced area of contact between the die and the metal container. Contact area is as characterized by WinSam (Surface Analysis Module for Windows) as described in ("Surface Characterisation in Forming Processes by Functional 3D Parameters,", S. Weidel, U. Engel, Int. J. Adv. Manuf. Technol. (2007) 33: 130- 136), which is incorporated herein by reference.
• the reduced friction enables metal containers to be expanded or narrowed to a greater degree in a single stroke of an expansion die or a necking die without damaging the container. Damage includes wrinkling, fracturing, ludering, collapse of the metal container or anything that diminishes the appearance of the metal container.
• Some embodiments of this invention look at topography of the textured surface using 3 -dimensional surface parameters and aim to minimize the area of contact of the tool with the work-piece.
• use of a textured surface on an expansion or necking die may have any combination of the following advantages: maximizing the extent of metal forming in a single stroke of an expansion or necking die without damaging the container due to decrease in friction, thus reducing the number of metal forming steps and reducing the amount of scrap; reducing the starting weight required to meet final product dimension specifications; eliminating the need to use lubricant when forming the metal containers.
• peening a die with precision balls results in a die that can form a metal container without defects more consistently than a highly polished die.
• Figure 1 depicts a cross-section of an expansion die having two lands
• Figure 2 is depicts a partial cross-section of the expansion die of Figure 1 ;
• Figure 3 depicts a cross-section of a die for narrowing a diameter of a metal container
• Figure 4 illustrates the direction of metal flow
• Figure S shows the inside diameter of a portion of the working surface of the necking die after it has been peened as described above;
• Figure 6 includes small field of vision images of the inside diameter of a portion of the working surface of the necking die shown in Figure 5;
• Figure 7 shows the surface topography of a ground surface
• Figure 8 is a chart showing the average transverse Ra of the both the peened surface and the ground surface shown in Figures 5-7;
• Figure 9 shows the surface topography of the peened working surface of an expansion die
• Figure 10 shows the surface topography shown in Figure 9 with corresponding line profiles showing the depth and height of indentations
• Figure 11 shows the bearing area curve of the peened working surface shown in Figures 9 and 10;
• Figure 12 shows the amount of forming load an expansion die having a peened working surface placed on a metal container during expansion of the container;
• Figure 13 shows forming energy of an expansion die having a peened working surface
• Figure 14 shows energy due to friction versus surface bearing area with respect to the non-peened surface
• Figure 15 shows energy due to friction versus surface bearing area with respect to the peened surface.
• FIG. 1 An exemplary expansion die 10 is shown in Figures 1 and 2.
• a work surface 12 comprising a progressively expanding portion 14 and a land 16 is shown.
• An undercut 18 is also illustrated.
• An exemplary die 30 having a work surface 32 configured to narrow a diameter of a metal container is shown in Figure 3.
• the work surface has a neck radius portion 34, a shoulder radius portion 36 and a land 38.
• a relief 40 is also shown.
• the work surface of a necking die was peened with 0.093" diameter Class 1000 balls.
• the quality of the balls was sufficient to minimize dust generation or fracture of the balls.
• Topography and roughness data is from the replica • All topography images from replicas have been inverted to depict the true topography of tiie die surface
• o Sci is the Core Fluid retention index. Sci>l indicates good fluid retention, o Svi is the Valley Fluid retention index. 0 ⁇ Svi ⁇ 0.2 with high Sci indicates good fluid retention in the valley areas,
• o Vcl is the closed void volume indicating the void volume at the surface available to trap fluids
• o Vop is the open void volume indicating the void volume at the surface that allows fluid to escape
• Figure 4 illustrates the direction of metal flow in relationship to the following topographic images.
• Figure 5 shows the inside diameter of a portion of the working surface of the necking die after it has been peened as described above.
• Figure 6 includes small field of vision images of the inside diameter of a portion of the working surface of the necking die shown in Figure 5.
• Figure 7 shows a ground, not peened surface.
• Figure 8 is a chart showing the average transverse Ra of the both the peened surface and the ground surface.
• FIG. 9 shows the surface topography of a portion of the working surface after peening.
• Figure 11 shows the bearing area curve of the peened portion of the working surface.
• the working surfaces of several expansion dies were modified by peening and the resulting effects on friction were compared to a baseline friction from a die surface that has been hard turned and lightly polished.
• the hard turned and lightly polished surface is not textured but has an Ra value of 8 to 10 Din. All other factors were held constant (Pre-Form, Tool Geometry, no air stripping used, no lubrication used). 10 samples were taken for each surface combination.
• a "B Ball” is a precision ball having 1/16th inch diameter.
• a “C Ball” is a precision ball having a 3/32 inch diameter.
• Tool surfaces were characterized by Sa (3-D parameter for Surface Roughness), Vcl (Normalized Closed Void Volume), aclm (Maximum Ratio of the Closed Void Area(/total area measured)) and percent contact area for each surface finish.
• Strain Energy was calculated using Finite Element Analysis using the given Tool and Pre-Form Sample Geometry to provide Forming Energy in a frictionless state. Friction data was then tabulated by subtracting the Strain Energy from the Forming Energy totals to arrive at Energy figures due to Friction.
• Results are provided with a Percent Change in Friction Energy for each surface characterized in percent contact area.
• Figure 12 shows the amount of forming load the expansion die placed on the metal container.
• Figure 13 shows forming energy.
• Figure 14 shows energy due to friction versus surface bearing area with respect to the non-peened surface.
• Figure 15 shows energy due to friction versus surface bearing area with respect to the peened surface.
• top, bottom, below, above, under, over, etc. are relative to the position of a finished metal container resting on a flat surface, regardless of the orientation of the metal container during manufacturing or forming steps or processes.
• a finished metal container is a metal container that will not undergo additional forming steps before it is used by an end consumer.
• the top of the container has an opening.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Crystallography & Structural Chemistry (AREA)
• Mounting, Exchange, And Manufacturing Of Dies (AREA)
• Containers Having Bodies Formed In One Piece (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)
• Shaping Metal By Deep-Drawing, Or The Like (AREA)
• Crystals, And After-Treatments Of Crystals (AREA)
• Manufacturing Optical Record Carriers (AREA)

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• 2013
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