WO2010048727A1 - Matrice à rétreindre avec surface pour emboutissage de reprise et procédé de rétreinte - Google Patents

Matrice à rétreindre avec surface pour emboutissage de reprise et procédé de rétreinte Download PDF

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Publication number
WO2010048727A1
WO2010048727A1 PCT/CA2009/001566 CA2009001566W WO2010048727A1 WO 2010048727 A1 WO2010048727 A1 WO 2010048727A1 CA 2009001566 W CA2009001566 W CA 2009001566W WO 2010048727 A1 WO2010048727 A1 WO 2010048727A1
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WO
WIPO (PCT)
Prior art keywords
die
redraw
wall
necking
container
Prior art date
Application number
PCT/CA2009/001566
Other languages
English (en)
Inventor
Karam Singh Kang
Original Assignee
Novelis Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Novelis Inc. filed Critical Novelis Inc.
Publication of WO2010048727A1 publication Critical patent/WO2010048727A1/fr

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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
    • B21D51/00—Making hollow objects
    • B21D51/16—Making hollow objects characterised by the use of the objects
    • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
    • B21D51/2615—Edge treatment of cans or tins
    • 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
    • B21D45/00—Ejecting or stripping-off devices arranged in machines or tools dealt with in this subclass
    • B21D45/02—Ejecting devices
    • 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
    • B21D51/00—Making hollow objects
    • B21D51/16—Making hollow objects characterised by the use of the objects
    • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
    • B21D51/2615—Edge treatment of cans or tins
    • B21D51/2638—Necking

Definitions

  • This invention relates to the shaping of metal containers by means of a succession of necking steps using dies that gradually modify the container walls into a desired finished shape. More particularly, the invention relates to the design of dies to improve die necking operations and to methods of die necking.
  • Thin walled metal foodstuff containers, beverage cans, aerosol canisters, and other such containers for consumer or industrial products are often provided with inwardly- or outwardly-flared walls for esthetic reasons or for reasons of practicality or economy.
  • beverage can bodies are often provided with an inward flare adjacent to their upper ends primarily to reduce the size of the required metal end closure walls.
  • Such end closure walls are necessarily made of a metal of a much thicker gauge than that required for the walls of the container bodies, so any reduction in their size results in a considerable saving of metal.
  • Containers of this kind are often made from rolled metal sheet that is cut into blanks, cupped, drawn and ironed to elongate the side walls, and then finally trimmed to produce a straight-walled open-ended container body pre-form.
  • Such container body pre-forms are then provided with flared ends or other shapes of the above-mentioned kind by a process known as die necking whereby the open end of a tubular pre-form is forced into or onto a succession of shaped annular dies of ever-decreasing (or increasing) diameter until the desired size reduction (or enlargement) of the tubular wall at the open end is achieved.
  • a large number of small changes of diameter are carried out in order to avoid metal buckling, ripping or tearing that generally occurs if abrupt size changes are attempted in a single step.
  • the extreme end of the container may exhibit circumferential lines or ripples that are visible in the finished article and detract from the desired smooth transition from one container diameter to another. These lines may result from the tendency of the metal to spring-back due to its elasticity, and this is made possible by the degree of free play between the die and associated knockout punch that allows the container wall to wrinkle slightly and prevents the wall from adopting an exact shape intended by the design of a necking-in die.
  • Ball Corporation discloses a procedure in which a plurality of venting ports are incorporated into a necking assembly which performs the necking operation.
  • the container body may be centered with respect to the necking assembly which produces a double-neck container body configuration.
  • the die set comprises a combination of a die and a knockout punch for the die having a generally cylindrical surface.
  • the die has, in an axial direction from front to back of the die, an inwardly tapering necking surface having an inflection point at an innermost end thereof, preferably an undercut portion having a generally cylindrical surface extending axially rearwardly from the inflection point, a convex redraw surface extending inwardly of the die from a rear of the generally cylindrical surface of the undercut portion, and a generally cylindrical cutback surface having a diameter larger than the redraw surface at a peak thereof and extending axially from the redraw surface towards the back of the die, wherein the redraw surface at the peak defines an opening dimensioned to receive the knockout punch with a spacing effective to redraw a wall of a container necked in the die.
  • annular necking die which comprises, in a direction from front to back of the die, a tapering necking surface of decreasing diameter having an inflection point at an innermost end thereof, preferably an undercut portion having a generally axial surface, a convex redraw surface extending inwardly of the die from the generally axial surface of the undercut portion, and a cylindrical cutback surface having a diameter larger than the redraw surface and extending from the redraw surface towards the back of the die, wherein, during use of the die in a necking-in operation carried out on a cylindrical wall of a hollow metal container pre-form in conjunction with a cylindrical knockout punch dimensioned to fit snugly within the die, the redraw surface is positioned and dimensioned to contact a wall of the pre-form and to compress the wall against the knockout punch, thereby smoothing out circumferential irregularities of the wall caused by wall-thickening as the pre-form is necked in.
  • Yet another exemplary embodiment provides a method of necking-in a metal container pre-form having a cylindrical wall and an open end, the method comprising carrying out a plurality of necking-in steps by introducing the open end of the container into necking-in dies operated with cooperating knockout punches, wherein for at least one of the steps, the container wall is both reduced in diameter and the container wall is redrawn to minimize circumferential irregularities of wall thickness caused by the reduction in diameter.
  • Still another exemplary embodiment relates to a method of providing a necking- in die with capability of container wall redrawing, which comprises cutting an annular groove into a surface of a cylindrical land of a necking-in die and inserting in the groove an element having a convex redraw surface extending inwardly beyond the surface of the land.
  • the container wall generally has a range of angles through which it may be bent plastically, and wherein, during at least one step, the container wall is bent through an angle within the range.
  • the wall is preferably redrawn by forcing the wall through an annular gap within a necking-in die set comprising a die and a knockout punch, wherein the annular gap is formed between a redraw surface on the die and an external surface of the knockout punch positioned rearwardly of an inflection point on a necking-in surface of the die, and wherein the annular gap has a width that is the same as or less than an average thickness of the container wall at the inflection point.
  • a lubricant is fed to the container wall as the wall is passed through the gap.
  • Fig. IA is a chart showing an outline of a typical shaped container body which the exemplary embodiments may produce (bottle profile diameter versus height), and Fig. IB indicates the degrees by which the wall will bend and unbend at different positions along the axis of the container body (bottle profiles of gradients versus height);
  • Fig. 2 is a partial cross-section of an annular die and associated knockout punch showing a die necking operation and the problems associated therewith;
  • Fig. 3 is a partial cross-section similar to that of Fig. 2, but showing an exemplary embodiment of the present invention;
  • Fig. 4 is an enlargement of the part of Fig. 3 surrounded by the dotted circle marked IV;
  • Figs. 5A and 5B are exaggerated schematic representations of transverse cross- sections of a container following necking-in; Fig. 5A shows radial variation of wall thickness, and Fig. 5B shows a smoothing of such variation obtainable by exemplary embodiments of the present invention;
  • Fig. 6 is a partial cross-section similar to Fig. 3 illustrating a profile of a die according to another exemplary embodiment of the invention
  • Fig. 7 is a view similar to that of Fig. 6 showing yet another profile according to yet another exemplary embodiment of the invention.
  • Fig. IA is a chart showing an arbitrary but typical shape of a metal bottle of the kind of which manufacture is currently being attempted by die necking operations.
  • the upper and lower curved lines A and B represent the walls of the container and it can be seen that it is intended to provide the container with a straight section C as well as a tapering shoulder D leading to a narrow cylindrical neck E.
  • Such a shape is often made up of a number of curves comprising a mixture of intersecting circles of varying diameters.
  • the slope of the shoulder D in the shape of Fig. IA may be continuously smooth or may be a linearly increasing curve which reaches a maximum before it decreases.
  • Fig. IA is a chart showing an arbitrary but typical shape of a metal bottle of the kind of which manufacture is currently being attempted by die necking operations.
  • the upper and lower curved lines A and B represent the walls of the container and it can be seen that it is intended to provide the container with a straight section C as well as a tapering shoulder D leading to a
  • line F represents the transitions in slope of the parts of the wall considered from the closed end to the open end of the container.
  • the metal undergoes a considerable degree of bending (possibly up to 55°, depending upon the bottle bottom base to neck diameters) and the difficulties mentioned in the introduction of this specification may be especially apparent.
  • the straight portion E on the neck approaches the die at zero degrees and encounters a die necking surface angled inwardly at say 18 degrees to create a bend. The wall will then bend back 18 degrees to form the shape shown in Fig. IA at the last necking die.
  • Fig. 2 is a schematic representation of a necking-in die and knockout punch combination 100 illustrating a necking-in step that may typically be attempted to produce a metal bottle of the kind described above.
  • a cross- section of the end part of only one half of a metal container pre-form 10 (referred to simply as the "container" in the following) is shown, and similarly, only a cross-section of half of a necking-in die 11 and a knockout punch 12, but the illustrated profiles are present all around the wall of the container, the die and the punch and are symmetrical around a central longitudinal axis of the die.
  • the wall 13 of the metal container is necked-in upon being pushed into the inwardly-tapering surface 18 of the annular necking die 11 while surrounding the knockout punch 12.
  • the latter is generally cylindrical except for an enlarged step 19 used for the knock-out procedure at the end of the necking-in step.
  • curve 14 is a neck-shape formed on the container at a previous necking station (this embodiment being different from that shown in Fig. IA).
  • Letters P, Q, R, S and T are used to identify different points on the die 11.
  • Point T represents the front of the die at its maximum opening diameter, and points R and S indicate the rear wall of the die.
  • the container 10 is moved relative to the die in the direction X during a necking operation and the knockout punch 12 is also moved in direction X at approximately the same speed during this stage of necking.
  • the surface 18 between points T and P causes the container pre-form to neck-in (i.e. to bend in) as it is pushed into the die.
  • the length of this surface is typically 0.02 - 0.5 inch, depending on the dimensions of the container pre-form and the necking step involved.
  • the thickness of the container wall is caused to increase as it passes along this surface as a consequence of the reduction in diameter of the necked-in part of the container.
  • Point P on the die is referred to as an inflection point and it may contain a small forming radius. This is the point where the metal loses contact with the surface 18 and the slope of the container wall is caused to bend dramatically upon contact with an outer surface 22 of punch 12.
  • a radial component of frictional force generated upon contact with the surface 18, and acting in the in the direction PT, also aids in forcing the container wall to bend back towards the die.
  • the profile of the die forms a cylindrical land 15 having a diameter that is intended to define the diameter of the neck of the container at this stage of the necking operation and a wall that is parallel to the axis of the die.
  • the metal of the container wall is not fully plastic and has a retained elasticity, and because there may be insufficient radial force from the friction generated with the contact with surface 18, and further because there is normally a gap or degree of play between the land 15 of the die 11 and the outer surface 22 of the punch 12 that is greater than the thickness of the wall of the container (to prevent the metal jamming in the die), the wall follows a curve 16 (which in actuality may rebound between the land 15 and the surface 22 several times) that extends above the land 15 by an amount that may be as large as 0.002 inches. The metal then reverse bends (relaxes) towards the end of the land 15 (at point Q).
  • the curve 16 thus formed may have a radius 1 V 1 " but this radius tends to be smaller than that which would allow the metal to bend plastically.
  • S yield strength
  • a large radius at point P is desired to decrease the angle of contact made between the metal at the inflection point, at first contact with the knockout punch, such that the normal component of the axial stress from friction and ram force remains high to avoid the arc above the land.
  • the land 15 normally extends axially in the region PQ by a distance of 0.1 to 0.2 inch or more and is then followed between points Q and R by a cylindrical cut-back region 17 of greater diameter than the land 15 and that consequently does not exert any significant force on the adjacent wall of the container during the necking operation (as there is no contact).
  • the cut-back region 17 prevents the pre-form from becoming jammed in the die and allows for the accumulation of debris and dirt without harmful effects on the necking operation.
  • the large amount of space between the die and the punch in the cut-back region 17 may allow the container wall to ripple or wrinkle into small waves (as represented in Fig. 2) to take up the available space.
  • Such rippling may occur in a space that is larger than required and is the result of the compressive forces created as the pre-form is pushed into the die. However, this rippling does not always occur as the contact between the container wall and the knockout punch may cause the container wall to remain in close contact with the surface 22 of the punch.
  • Fig. 3 shows a die profile similar to that of Fig. 2, but illustrating one exemplary embodiment of the invention. The part of Fig. 3 within the broken-line circle IV is shown in greater magnification in Fig. 4. In this exemplary embodiment, the land 15 of Fig. 2 (shown in dotted lines in Fig.
  • the contact is such that only parts of the metal wall thickened more than average during the necking-in step are flattened and redrawn to a desired average thickness of the container wall, but the contact may be made such that a slight reduction in the average wall thickness is also achieved.
  • This thickness reduction is generally less than 10% of the average thickness of the contacted container wall, more preferably less than 5%, and may (as noted) be essentially zero (the intended average wall thickness at this position in the die).
  • Figs. 5A and 5B show in a very simplified schematic way the "redrawing" that takes place at this position. Fig.
  • FIG. 5A represents a cross-section of the container immediately in advance of the contact with the redraw element 20 and shows how the thickness may vary around the circumference of the metal wall (radial variations in thickness). A form of wrinkling or pleating may occur particularly around the 0° and, to a lesser extent, the 90° axes to the rolling direction of the sheet from which the container is made (due to metal anisotropy).
  • Fig. 5B after contact with the redraw element 20 backed by the knockout punch 12, the profile of the wall is smoothed out to a constant thickness "t" (which may be slightly less than the wall thickness of the container shown in Fig. 5A) and is smoothed to an average surface evenness.
  • the container may jam in the die or undergo buckling and result in a failure of the necking step.
  • the optimum is therefore to make the contact brief (extending over a minimal axial distance) and with minimum friction, but significant enough to create the desired redrawing effect. This is made possible by the convex nature of surface 21 which is such that the surface extends away from the container wall immediately beyond the point of contact (actually a circumferential line of contact around the die).
  • the element 20 should preferably be shaped and positioned such that the wall of the container may contact the element without being lifted away from the surface 18 or bent inwardly towards the center of the die. More preferably, the die is positioned such that the metal may bend slightly outwardly, following point P, before contacting the element 20. This is illustrated in Fig. 4 by arrow K that is slightly bent towards the right at the head end.
  • the inflection point P is immediately followed (in the axial direction front to back of the die) by an undercut portion 25 similar to the start of the land 15 of a die of the kind of Fig. 2 but provided at a greater distance from the center of the die.
  • This undercut portion 25 is preferred (but not essential) to form a reservoir for lubricant for the metal in advance of the redrawing process.
  • the lubricant in the reservoir may be replenished during the knockout process when the container is removed from the die (lubricant is generally liberally applied to the die and knockout punch during the necking operation and is thus available for replenishment of the reservoir).
  • the presence of the undercut portion 25 also avoids support for the container wall beyond the inflection point P.
  • the undercut portion 25 preferably has a generally axial (cylindrical) surface at its maximum diameter (i.e. it may be exactly axial as shown or slightly sloping up or down relative to the die axis). If the undercut portion 25 is absent, the die surface in this region may follow the contour of the original land 15 as shown in broken lines.
  • the redraw surface 21 rises beyond the undercut portion 25 (and the surface of the original land 15) as shown and engages the outer (lower) surface of the container wall 13 as the metal curves under the bending force imposed by the knockout punch 12 and the frictional force.
  • the redraw surface is convex and has a peak 23 at which it is closest to the central axis of the die.
  • the maximum height "h 2 " of the redraw surface 21 above the surface of the original land 15 causes a reduction in the diameter of the container wall at this point by an amount of 2 x h 2 (as the container is necked in from all sides).
  • This height is chosen to cause the neck 26 of the container to become reduced in wall thickness by the indicated amount of less than 10%, and consequently to elongate the metal slightly as it is extruded.
  • Height “h 2 " is preferably l/20 th (5%) of the wall thickness at a maximum and l/200 th (0.5%) of the wall thickness at a minimum so that, as explained previously, the metal is deformed plastically in the curve.
  • the distance “h 2 " is generally from 0.0001 to 0.012 inch, preferably 0.0001 to 0.006 inch, depending on wall thickness and the stage of the necking operation.
  • the redraw surface 21 is preferably in the form of a convex curve or arc that has a radius "r 2 " (see Fig. 3).
  • the radius is chosen according to the desired reduction of wall thickness. Generally, the radius varies from 0.02 to 4 inches. As the number of necking steps increases, the metal may become harder and it may be preferable to reduce the radius "r 2 ", e.g. to a range of 0.02 to 2 inches with a base "x" (see Fig. 4) ranging from 0.4 to 0.03 inch.
  • the radius "r 2 " is preferably determined by the formula:
  • the curve on the redraw side is longer and thus the pinch starts just before the minimum gap between the knockout punch and the peak 23 of the redraw radius.
  • the metal flow can be preferentially controlled over the redraw radius.
  • the dimensions and positioning of the redraw element 20 or surface 21 depends to some extent on the thickness and nature of the metal of the wall of the container.
  • the metal is usually steel or an alloy of aluminum. In the latter case, the following metal thickness ranges are usual: 0.002-0.080 inch (0.051-2.03 mm), and more preferably 0.005-0.025 inch (0.127-0.635 mm).
  • the action of the redraw element 20 helps to avoid the previously- described wrinkle or ripple in the neck region 26 positioned beyond the redraw element 20.
  • the diameter of the cutback region may therefore be less than the diameter of the surface of the undercut portion 25 ahead of the redraw element 20, as shown in Figs. 3 and 4.
  • the step 19 at the end of the knock-out punch is a bearing surface that may ride on the cut-back surface 17 and may always be in contact with this surface.
  • the small gap or clearance "h 3 " allows the step 19 to slide on the surface 17 with minimum friction as the knockout punch usually moves slightly faster than the metal during the necking operation.
  • the gap "h 3 " is preferably in the range of 0.001 inch to 0.000050 inch, e.g. about 0.0007 inch. The lower end of the range may be achieved by setting this gap effectively to zero and then roughening the surface 17 to a roughness value (R a ) of 5 to 10 micro-inches and polishing off the peaks to create a run-in surface which acts as lubrication bearing surface for the knockout punch.
  • the lubrication is transferred to the entry side of the element 20 into the undercut portion 25 above P in Fig. 4 (a pumping action of the larger diameter step 19 of the knockout punch), which acts as a reservoir for lubricant for reducing the redraw ironing force for the next stroke.
  • a redraw element 20 positioned within a slot 28 within the region of the land 15 of a die of the type shown in Fig. 2
  • the die itself may be provided with an internal shape provided with a redraw surface 21 and (if desired) an undercut portion 25.
  • Figs. 6 and 7 show alternative profiles.
  • Fig. 6 shows the profile of a die 11 having a necking-in zone TP, and inflection point P, an undercut portion 25, a convex curved redraw surface 21, and a cut-back region 17. The position of a land 15 of the type shown in Fig.
  • Fig. 7 the surface of the undercut portion 25 is not quite axial (it slopes or tapers slightly radially inwardly towards the central axis of the die) and the redraw surface 21 is asymmetrically shaped to minimize contact at the entry side.
  • the provision of a smooth arc for surface 21 is normally considered preferable, but the shape of Fig. 7 may be useful if a sharper radius is required to fit into the area previously forming the land.
  • the preferred radius at P is one that is as long as possible for a smooth transition to be obtained on the necked-in portion.
  • the profile of Fig. 7 allows a large radius at P while providing the required undercut portion 25.
  • the drawings of the present application show a single die and knockout punch set designed for one of many necking-in steps of a particular shaping operation. Each such operation will have a specially designed die and knockout punch set as the profile of the container is gradually shaped to a final profile.
  • Each of these dies may be provided with a redraw surface according to the exemplary embodiments, but it is more usual to provide the surface in only those dies used for the last few steps. This is because the deformities in the container shapes start out small and build up with each successive necking step, so it is only at the end stages where the deformities are significant and need to be corrected. The number of dies needing a redraw surface can easily be determined by trial and error, or with the benefit of experience.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

L'invention porte sur un ensemble matrice comprenant une matrice à rétreindre annulaire et un poinçon éjecteur pour former un col dans un contenant métallique, et sur un procédé de rétreinte. Dans le procédé, dans au moins une étape de rétreinte, le contenant métallique est à la fois réduit en diamètre et la paroi de contenant est réembouti afin de rendre minimales les irrégularités périphériques de l'épaisseur de paroi et/ou l'ondulation périphérique de la paroi de contenant, provoquées par la réduction de diamètre. La matrice de l'ensemble matrice comporte une surface pour emboutissage de reprise afin d'obtenir cet effet d'emboutissage de reprise.
PCT/CA2009/001566 2008-10-31 2009-10-30 Matrice à rétreindre avec surface pour emboutissage de reprise et procédé de rétreinte WO2010048727A1 (fr)

Applications Claiming Priority (2)

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US19797508P 2008-10-31 2008-10-31
US61/197,975 2008-10-31

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WO2010048727A1 true WO2010048727A1 (fr) 2010-05-06

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US10934104B2 (en) 2018-05-11 2021-03-02 Stolle Machinery Company, Llc Infeed assembly quick change features
US11097333B2 (en) 2018-05-11 2021-08-24 Stolle Machinery Company, Llc Process shaft tooling assembly
US11117180B2 (en) 2018-05-11 2021-09-14 Stolle Machinery Company, Llc Quick change tooling assembly
US11208271B2 (en) 2018-05-11 2021-12-28 Stolle Machinery Company, Llc Quick change transfer assembly
US11370015B2 (en) 2018-05-11 2022-06-28 Stolle Machinery Company, Llc Drive assembly
US11420242B2 (en) 2019-08-16 2022-08-23 Stolle Machinery Company, Llc Reformer assembly
US11534817B2 (en) 2018-05-11 2022-12-27 Stolle Machinery Company, Llc Infeed assembly full inspection assembly
US11565303B2 (en) 2018-05-11 2023-01-31 Stolle Machinery Company, Llc Rotary manifold

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US9358604B2 (en) 2014-06-12 2016-06-07 Ball Corporation System for compression relief shaping
US20210178449A1 (en) * 2017-12-28 2021-06-17 Daiwa Can Company Aerosol can having surface pattern on trunk portion and manufacturing method thereof
CN112916735B (zh) * 2021-02-02 2022-09-27 中国航发长春控制科技有限公司 一种滤网组件收口装置及使用该装置收口滤网组件的方法
CN117583485B (zh) * 2024-01-17 2024-03-26 山东朝日不锈钢有限公司 一种不锈钢管件缩口模具及其方法

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Cited By (8)

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Publication number Priority date Publication date Assignee Title
US10934104B2 (en) 2018-05-11 2021-03-02 Stolle Machinery Company, Llc Infeed assembly quick change features
US11097333B2 (en) 2018-05-11 2021-08-24 Stolle Machinery Company, Llc Process shaft tooling assembly
US11117180B2 (en) 2018-05-11 2021-09-14 Stolle Machinery Company, Llc Quick change tooling assembly
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