WO2019188324A1 - 金属加工物 - Google Patents
金属加工物 Download PDFInfo
- Publication number
- WO2019188324A1 WO2019188324A1 PCT/JP2019/010478 JP2019010478W WO2019188324A1 WO 2019188324 A1 WO2019188324 A1 WO 2019188324A1 JP 2019010478 W JP2019010478 W JP 2019010478W WO 2019188324 A1 WO2019188324 A1 WO 2019188324A1
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- WIPO (PCT)
- Prior art keywords
- ironing
- blank
- reflected light
- measured
- processing
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/12—Cans, casks, barrels, or drums
- B65D1/14—Cans, casks, barrels, or drums characterised by shape
- B65D1/16—Cans, casks, barrels, or drums characterised by shape of curved cross-section, e.g. cylindrical
- B65D1/165—Cylindrical cans
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- 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
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/01—Selection of materials
-
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
- B65D1/26—Thin-walled containers, e.g. formed by deep-drawing operations
-
- 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
- B21D22/30—Deep-drawing to finish articles formed by deep-drawing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/40—Details of walls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2203/00—Decoration means, markings, information elements, contents indicators
Definitions
- the present invention relates to a metal workpiece such as a squeezed iron blank can, and more particularly to a metal workpiece in which damage to the surface to be processed during plastic processing is suppressed.
- an aluminum can widely used for beverage cans there is a two-piece aluminum can (DI can) manufactured by drawing and ironing using a liquid such as a coolant.
- DI can two-piece aluminum can
- Aluminum cans are generally continuously produced in factories, but as the number of cans increases, there is a problem that the metal of the work piece adheres to the ironing die used for drawing ironing (adhering) .
- the outer surface of the body is parallel to the ironing direction, that is, a fine vertical flaw occurs in the can height direction. If the outer surface of the can body part is vertically damaged, the mirror surface of the outer surface of the body part is degraded, and the appearance of the mirror image changes depending on the viewing direction. Therefore, establishment of adhesion suppression technology is required.
- Patent Document 1 discloses that a hard thin film having a Vickers hardness of 2500 or more is coated on a surface of a die base that is in contact with a metal base plate as a die for at least the final stage of ironing.
- a drawing ironing method using a die whose surface roughness Ra of the hard thin film is 0.05 ⁇ m or less has been proposed. That is, in the squeezing and ironing method disclosed in Patent Document 1, ironing is performed using a die provided with a smooth hard film, thereby suppressing metal adhesion to the die surface.
- the hard film of the die disclosed in Patent Document 1 is made of diamond-like carbon, and such a hard film is easy to peel off and has low durability and high surface pressure. Under such conditions, there are problems such as insufficient adhesion suppression effect. Therefore, the squeezing and ironing method disclosed in Patent Document 1 cannot be applied to the production of beverage cans and the like having severe processing conditions, and the field of application is limited.
- an object of the present invention is to provide a metal workpiece in which damage to the surface to be processed is suppressed during plastic processing for the purpose of thinning or reducing the diameter.
- the arithmetic average roughness Ra1 measured in the direction orthogonal to the processing direction and the arithmetic average roughness measured in the processing direction of the surface to be processed is provided.
- the arithmetic average roughness Ra1 measured in a direction orthogonal to the processing direction is 0.030 ⁇ m or less.
- the regular reflected light with respect to the incident light incident at 45 degrees in the direction orthogonal to the processing direction and the processing direction as a reference the brightness L of the reflected light having an angle of 15 degrees with respect to the direction of the regular reflection light orthogonal lightness L 15h value of the reflected light having an angle of 15 degrees with respect to the working direction of the specular reflection light and the machining direction
- the ratio L 15w / L 15h to the 15w value is 0.7 to 1.3, and the lightness L 15h value in the processing direction is greater than 50.
- a drawn and ironed blank can made of an aluminum alloy and obtained by drawing and ironing, and in a can after 35,000 cans continuously made, in the circumferential direction of the outer surface of the trunk portion
- a squeezed iron blank can characterized in that the ratio Ra1 / Ra2 between the measured arithmetic average roughness Ra1 and the arithmetic average roughness Ra2 measured in the height direction of the outer surface of the body is 0.5 to 1.5.
- a drawn can obtained by drawing a metal disc is provided with a diamond film and has a processed surface having a surface roughness Ra of 0.1 ⁇ m or less.
- a method for producing a drawn and ironed blank can characterized in that a drawn and ironed blank can is obtained by performing a drawing and ironing process using a die.
- the drawn and ironed blank can means a molded body obtained by drawing and ironing and before being subjected to neck-in processing or the like.
- the surface to be processed means a surface on which wear powder, which is one of the causes of adhesion, can be generated by plastic working.
- wear powder which is one of the causes of adhesion
- plastic working for example, in the case of a squeezed and ironed blank can, it means the outer surface of the body part.
- both front and back surfaces are processed surfaces.
- the present invention is a metal workpiece obtained by plastic working for the purpose of thinning or reducing the diameter, such as a drawn iron blank can obtained by drawing ironing.
- a drawn iron blank can obtained by drawing ironing.
- both are low. This indicates that there is no linear processing trace extending in the processing direction on the surface to be processed. That is, in the metal workpiece of the present invention, drawing and ironing during plastic processing, particularly during continuous can making. It shows that the damage to the surface to be processed at the time is suppressed.
- the metal workpiece in which scratches on the surface to be processed are suppressed can be stabilized by plastic working using a die having a diamond film and a surface having a surface roughness Ra of 0.1 ⁇ m or less. Can be produced continuously.
- the schematic sectional side view of the blank can which is 1 aspect of this invention.
- the figure which shows the outline of the redraw ironing process implemented after the drawing process of FIG. The figure explaining the evaluation principle of the reflected light using a multi-angle spectrocolorimeter.
- the present invention relates to a metal workpiece, and as one aspect thereof, for example, there is a squeezed iron blank can (hereinafter simply referred to as a blank can).
- the blank can is a molded body obtained by ironing, which will be described later, and before post-processing such as neck-in processing, and therefore has a very simple form as shown in FIG.
- the present invention will be described in detail with a blank can.
- the blank can of this aspect shown by 10 has the bottomed cylindrical shape as a whole, the straight trunk
- the longitudinal outer surface which is the surface to be processed, has almost no long vertical scratches in the can height direction.
- a blank can is manufactured as follows. ⁇ Manufacture of blank cans>
- the blank can of this embodiment is produced mainly by a forming process using a metal plate known per se.
- the metal plate to be subjected to the forming process such as an aluminum plate, may be pure aluminum or an alloy of aluminum and another metal, for example, an aluminum alloy containing magnesium or manganese.
- the plate material may be another metal such as iron, titanium, magnesium, or an alloy mainly made of another metal, or a plated plate such as tinplate.
- the metal plate is preferably made of an aluminum alloy.
- the surface of the metal plate may be resin-coated, for example, a thermoplastic resin film such as a polyester resin typified by polyethylene terephthalate may be laminated. It is preferable to coat the inner surface of the can with a resin since the corrosion resistance of the inner surface of the can is enhanced, or to form a coating film on the inner surface of the can after spraying using means such as spraying. Since the surface on the outer surface side of the can is damaged in specularity, it is preferable that the surface of the can is not coated with a resin, or even if the thickness is less than 100 nm. Further, a treatment film may be formed on the surface of the metal plate by anodic oxidation, chemical conversion treatment, or the like, but it is preferable not to form it because the specularity is impaired.
- FIG. 2 shows an outline of punching and drawing in this forming process.
- FIG. 3 shows an outline of the redraw ironing process.
- the base plate 11 made of the above-described metal material is first subjected to a punching process, thereby obtaining a can disc (blank) 13 (see FIG. 2A).
- a punching punch 15 having an outer diameter corresponding to the diameter of the disk 13 and a die 17 that holds the base plate 11 and has an opening corresponding to the diameter of the disk 13 are used.
- the base plate 11 held on the die 17 with the punch 15 the disc 13 having a predetermined size is obtained.
- the obtained disk 13 is subjected to a drawing process, whereby a drawn can (bottomed cylindrical body) 19 having a low height is obtained (see FIG. 2B).
- a drawn can (bottomed cylindrical body) 19 having a low height is obtained (see FIG. 2B).
- the disk 13 is held on the die 21.
- the periphery of the disk 13 is held by a wrinkle pressing jig 23.
- An opening is formed in the die 21, and the squeezing can 19 is obtained by pushing the disc 13 into the opening of the die 21 using the punch 25 for squeezing.
- a round portion (curvature portion) is formed at the corner portion (the side holding the disc 13) of the upper end of the opening of the die 21 so that the disc 13 can be quickly and without breaking inside the opening of the die 21. It will be pushed into.
- the outer diameter of the punch 25 is set smaller than the diameter of the opening of the die 21 by an amount corresponding to the thickness of the disk 13. Therefore, thinning is hardly performed in this drawing process.
- the squeezed can 19 obtained as described above is subjected to the redrawing ironing process shown in FIG. Thereby, the blank can base
- the ring-shaped redraw die 31 and the plurality of ironing dies 33a to 33c are arranged in this order, and are located on the most downstream side with respect to the machining direction.
- a guide ring 35 is disposed on the downstream side of the ironing die 33c, and a holding ring 37 and a holding rod 37a for bottom molding are provided in this order on the downstream side.
- the ironing dies 33a to 33c have a shape such that the diameter gradually decreases toward the downstream side in the processing direction, so that the thickness is reduced.
- the drawing can 19 is held on the redraw die 31 by the holder 41.
- the ironing punch 43 is inserted into the drawing can 19 and the dies 31, 33a to 33c are inserted.
- the punch 43 is moved in the processing direction while the outer surface of the drawn can 19 is pressed against the inner surface (processed surface), redrawing and ironing is performed, and the side wall of the drawn can 19 becomes thinner.
- the blank can 10 is obtained which is thinned and has a high height according to the degree of thinning. Under wet conditions, at this time, a liquid such as a coolant is appropriately supplied to the surface to be processed so that the lubrication is not lost.
- the tip of the ironing punch 43 has a tapered shape corresponding to the bottom 3 of the blank can 10 described above.
- the holding ring 37 is provided so as to be slidable along the machining direction.
- a holding rod 37a is inserted in the center of the ring, and the inner peripheral surface of the holding ring 37 and the upper end of the holding rod 37a are blank. It has a shape corresponding to the bottom of the can 10. That is, the squeezing can 19 is pushed out by the ironing punch 43 through the dies 31, 33a to 33c described above, and the bottom of the ironing can 19 is processed by the holding ring 37 and the holding rod 37a.
- the shape of a predetermined bottom part is shaped by this and the blank can 10 is obtained.
- the ironing punch 43 is moved upstream in the processing direction, and the obtained blank can 10 is pulled out of the ironing punch 43 by the guide ring 35 being held.
- the blank can 10 is taken out.
- the blank can 10 is subjected to post-processing such as trimming, neck-in processing, and winding processing for use.
- ironing dies are arranged and ironing is performed in three stages.
- the number of ironing dies is not limited to three. Depending on the thinning and the height of the can, it can be an appropriate number, can be ironed in one stage with one die, or two or more dies are arranged. Thus, ironing can be performed in multiple stages.
- the ironing process as described above is usually performed using an ironing die having an appropriate diameter and number so that the ironing rate defined by the following formula is 50% or less.
- Ironing rate (%) ⁇ (Thickness before ironing-Thickness after ironing) / Thickness before ironing ⁇ ⁇ 100
- the ironing process can be performed under wet conditions while flowing a coolant or the like, or can be performed under dry conditions without using coolant or the like. From the viewpoint that a smooth outer surface can be easily obtained, it is preferable to perform ironing under wet conditions.
- the outer surface of the body of the blank when the redrawing and ironing process is performed under wet conditions, the outer surface of the body of the blank can finally obtained is whitish compared to the dry condition. This is because the coolant is interposed between the mold and the surface to be processed, so the transfer rate of the mold surface to the outer surface of the body is low, the outer surface of the body is roughened, and the proportion of diffusely reflected light in the total reflected light is reduced. Because it becomes high.
- the ironing dies 33a to 33c a die having a diamond film provided on a processed surface (a surface contacting the outer surface of the drawn can 19 to be ironed) is used, and the diamond film is subjected to surface polishing. Therefore, it is necessary that the surface has a high smoothness. Of course, even when ironing is performed with a number of dies other than three, at least the final ironing die must have such a diamond film on the processing surface.
- the outer surface of the resulting blank can 10 has a linear processing mark in the ironing direction. This is because the diamond film is chemically stable, has low reactivity with the metal of the workpiece, and is excellent in durability because of its high hardness. Even a diamond-like carbon film (DLC film) does not reach the hardness of the diamond film.
- DLC film diamond-like carbon film
- cemented carbide as a material for forming the surface of a die for ironing which has been widely used conventionally, but the metal of the workpiece is adhered to the cemented carbide on the surface. If you continue to use the die where adhesion occurs, a long vertical scratch in the can height direction will be attached to the outer surface of the can body, eventually leading to a broken body.
- the surface of a die for ironing processing made of a cemented carbide alloy usually depends on conditions such as the speed of canning, but the metal adhered every few hours. Removal work is required. In the case of a diamond film, the work frequency is reduced at each stage.
- a diamond-like carbon film is a surface film that has been attracting attention in recent years, but the DLC film contains more impurities and has lower crystallinity than the diamond film. Therefore, the DLC film is easily peeled off and has low durability. Furthermore, in the ironing process in the continuous production of beverage cans, a particularly high surface pressure is repeatedly applied to the ironing die, but in the case of a DLC film, it has also been found that the adhesion suppressing effect is low under such a high surface pressure.
- the diamond film is provided on at least the processing surface of the ironing dies 33a to 33c made of a normally used rigid base material.
- a rigid substrate a material having a rigidity capable of withstanding severe ironing with a high surface pressure and a heat resistance capable of withstanding high-temperature heating during the formation of a diamond film is used.
- Examples of such a material include so-called cemented carbide obtained by sintering a mixture of tungsten carbide (WC) and a metal binder such as cobalt, metal carbide such as titanium carbide (TiC), and titanium carbonitride ( Cermet obtained by sintering a mixture of a titanium compound such as TiCN) and a metal binder such as nickel or cobalt, or silicon carbide (SiC), silicon nitride (Si 3 N 4 ), alumina (Al 2 O 3 ), Examples thereof include hard ceramics such as zirconia (ZrO 2 ).
- the diamond film formed on the processed surface of the ironing die made of the rigid base as described above (ironing die) is not particularly limited.
- ID is the maximum peak intensity at 1333 ⁇ 10 cm ⁇ 1 in the Raman spectrum of the carbon film surface
- I G is the maximum peak intensity at 1500 ⁇ 100 cm -1 in the Raman spectrum of the carbon film surface
- a film having a strength ratio represented by is 1.0 or more, preferably 1.2 or more.
- Peak intensity I D is derived from the diamond component in the film
- the peak intensity I G is derived from a graphite component in the film. Therefore, the larger the peak intensity ratio is, the smaller the graphite content is, and a film closer to a diamond crystal (high-purity diamond film) is formed.
- Such a diamond film has a very high Vickers hardness of 8000 or higher, has high chemical stability, and suppresses reaction with the workpiece at the interface. Thereby, since sliding property becomes favorable, the tolerance with respect to severe ironing processing is very high.
- a diamond film having a peak intensity ratio smaller than the above range contains a large amount of components other than diamond components such as graphite, has low sliding properties and low resistance to ironing, and is liable to cause molding defects. If the peak intensity ratio is excessively large, the film becomes brittle and durability may be impaired. Therefore, the peak intensity ratio is preferably 5 or less.
- the diamond film having the peak intensity ratio as described above is produced by forming a film on the surface of a rigid substrate by a known method such as plasma CVD, for example, hot filament CVD, microwave plasma CVD, high frequency plasma CVD. .
- plasma CVD for example, hot filament CVD, microwave plasma CVD, high frequency plasma CVD.
- a gas obtained by diluting a hydrocarbon gas such as methane, ethane, propane, acetylene or the like with hydrogen gas to about 1% is generally used as the source gas.
- a small amount of gas such as oxygen, carbon monoxide, and carbon dioxide may be mixed as appropriate.
- the rigid substrate is heated to a high temperature of 700 to 1000 ° C., plasma is generated by microwaves or high frequency, and the active gas is generated by decomposing the raw material gas in the plasma.
- Film formation is performed by growing diamond crystals on the material.
- hydrogen atoms dissociated in the plasma selectively etch the graphite and amorphous carbon produced on the rigid substrate, thereby increasing the diamond component and the peak intensity ratio of the Raman spectrum of the film. Can be within the aforementioned range.
- a diamond film formed by means such as vapor deposition, particularly a diamond film having a peak intensity ratio as described above, is accompanied by etching of graphite or amorphous carbon during film formation, so that a diamond crystal easily grows and has a rough surface.
- the diamond film is hard and can withstand harsh ironing, but if it is subjected to ironing without polishing the surface of the diamond film as it is, it can be broken and cannot be formed, or even if it can, the outer surface of the can body can be smoothed. Can not do it. Therefore, it is important that the diamond film has a highly smooth surface by surface polishing.
- a blank in order to obtain a blank can having a smooth body outer surface, surface polishing is performed so that the surface roughness Ra (JIS B-0601-1994) of the diamond film is 0.1 ⁇ m or less, particularly 0.05 ⁇ m. Is called.
- the lower limit is usually 0.005 ⁇ m.
- the surface polishing of the diamond film can be performed by a method known per se.
- a mechanical polishing method that performs co-machining of a carbon film using diamond abrasive grains (grinding stone) or a polishing method that uses chemical action may be used.
- a polishing method combining these mechanical and chemical methods may be used.
- the blank can of this embodiment with a smooth outer surface of the body can be obtained by the punching, drawing and redrawing and ironing processes described above.
- ⁇ Blank can surface> (Surface roughness)
- the ratio Ra1 / Ra2 between the calculated arithmetic average roughness Ra1 and the arithmetic average roughness Ra2 measured in the height direction, that is, the machining direction is 0.5 to 1.5, preferably 0.8 to 1.2 and 1. Indicates a close value.
- the value of the circumferential direction arithmetic average roughness Ra1 of the outer surface of the trunk portion 1 is preferably 0.030 ⁇ m or less.
- the surface roughness Ra2 in the can height direction is not much different from the case where no vertical flaw is given, but the surface roughness Ra1 in the circumferential direction is not changed. As a result, the ratio Ra1 / Ra2 increases.
- the maximum height surface roughness Rz (JIS-B-0601-2001) of the outer surface of the body portion 1 is also the same as the arithmetic average roughness Ra, even if it is obtained by continuous canning, the circumferential direction Rz1
- the ratio Rz1 / Rz2 with respect to the height direction Rz2 shows a value close to 1, specifically 0.6 to 1.4.
- the blank can of this mode has a smooth outer surface of the body, that is, the outer surface of the body is like a mirror surface.
- the specularity can be evaluated by regular reflectance.
- the regular reflectance is high and light scattering due to irregular reflection is small.
- the incident light of any wavelength is The regular reflectance is high, and preferably 73 to 90% at a wavelength of 680 ⁇ 50 nm.
- both the regular reflectance measured in the circumferential direction and the regular reflectance measured in the can height direction show high values, that is, not only have high specularity but also a high specular surface. It is maintained even when the direction of gender changes. If the outer surface of the body portion has a processing mark, the regular reflectance in the can height direction does not change much, but the regular reflectance in the circumferential direction decreases.
- specularity can be confirmed from the viewpoint of regular reflectance as described above, but it can also be confirmed by measuring the surface to be processed with a multi-angle spectrophotometer and observing irregularly reflected light. can do.
- the work surface consisting of a curved surface such as the outer surface of the can body is visually observed in a situation where the amount of incident light is large, such as under a fluorescent lamp, the mirror image of the light source reflected on the work surface is white and dazzling, and the work surface is scratched. It is difficult to judge whether it is on or off because it is dazzling, but even in such cases, the presence of specularity is usually confirmed by visually checking the state of diffuse reflection (such as the brightness of the image reflected around the mirror image of the light source). it can. Thus, it is meaningful to measure irregularly reflected light as a measurement corresponding to the visual observation condition in an extremely bright environment.
- specularly reflected light incident light
- a predetermined substrate surface 51 corresponding to the outer surface of the body of the blank can
- the light is reflected in the direction of 45 degrees with respect to the substrate surface 51.
- the components of the light reflected in the directions of 15, 30, and 45 degrees with respect to the specularly reflected light are measured. In general, it is said that the amount of irregularly reflected light having an angle larger than 45 degrees with respect to regular reflected light is small.
- the L value (brightness) of the reflected light having the above-described angle with respect to the regular reflected light by the LCH method using a multi-angle spectrocolorimeter on the surface to be processed (blank can outer surface in the blank can).
- L * a * b * method also called Lab method
- LCH method uses color coordinates in Cartesian coordinates (orthogonal coordinates).
- the LCH method displays polar coordinates.
- colors are indicated by L, C and h, which have the following meanings.
- L indicates lightness (brightness). The closer the number is to 0, the darker the color, and the greater the number, the brighter.
- C means saturation (brightness). When this numerical value is small, the color is cloudy, and the larger the numerical value, the brighter the color.
- h is a hue angle, which is a value in the range of 0 to 360.
- 0 to 90 indicates red, orange, yellow, 90 to 180 indicates yellow, yellowish green, green, 180 to 270 indicates green, cyan (blue green), blue, 260 to 360 indicates blue, purple, and magenta.
- the L value of the reflected light having an angle of 15 to 45 degrees (in 15 degree increments) with respect to the regular reflected light with reference to the regular reflected light with respect to the incident light incident at 45 degrees in the can height direction Measure the L value (brightness) of the reflected light having an angle of 15 to 45 degrees (15 degree increments) except that the light is incident in the circumferential direction. Even in the reflected light, the L value is close to the can height direction and the circumferential direction.
- reflected light having an angle of 15 degrees with respect to regular reflected light is referred to as 15-degree reflected light.
- the method of irregular reflection is very similar between the can height direction and the circumferential direction, and the surface to be processed is scratched both in the processing direction and in the direction orthogonal to the processing direction. Absent.
- the blank can of this embodiment is manufactured by ironing using a iron plate having a specific diamond film on a processed surface using a metal plate.
- the brightness of the irregular reflection component of the mirror image reflected on the outer surface of the trunk portion increases, and the mirror image tends to appear whitish.
- the brightness L 15h of the 15-degree reflected light in the process direction shows a large value, preferably a value greater than 50, more preferably greater than 50 and 150. It is as follows.
- the transfer rate of the mold to the surface to be processed increases, so that higher specularity is obtained, and the lightness L 15h of reflected light of 15 degrees in the processing direction, which is a diffuse reflection component. Is 50 or less.
- the present invention has been described by taking a blank can as an example.
- the present invention is not limited to a blank can, and is obtained by thinning or reducing the diameter by plastic working and has the above-described characteristics.
- the metal workpiece of the present invention may be a rolled material obtained by thinning a metal plate by rolling.
- the rotation direction of the rolling roll is the processing direction
- the surface directly in contact with the rolling roll is the surface to be processed.
- both the front and back surfaces of the rolled material are processed surfaces.
- the metal workpiece of the present invention may be a wire drawing material obtained by reducing the diameter of a metal bar through a die having a tapered hole.
- the regular reflectance of incident light incident at 5 degrees in the processing direction (can body height direction) and the circumferential direction on the outer surface of the can body was measured.
- the outer surface of the can body portion using the rolled plate as a raw material includes a region where the rolling direction and the processing direction of the plate material are parallel and a region where the rolling direction and the processing direction are orthogonal to each other. Averaged as a measurement target.
- the reflected light on the outer surface of the body of the aluminum can was evaluated by the LCH method. Specifically, with reference to the regular reflection light with respect to the incident light incident at 45 degrees in the processing direction (can body height direction) and the circumferential direction of the can body part, it is orthogonal to the lightness L 15h in the reflected light of 15 degrees in the processing direction. The lightness L 15w with the reflected light in the direction 15 degrees was measured, and the ratio L 15w / L 15h was obtained.
- the lightness L 30h in the processing direction 30-degree reflected light and the lightness L 30w in the orthogonal direction 30-degree reflected light were measured, and the ratio L 30w / L 30h was obtained.
- the brightness L 45 w at lightness L 45h orthogonal direction 45 ° reflected light at the machining direction 45 degree reflection light was measured to determine the ratio L 45w / L 45h.
- both the region in which the rolling direction and the processing direction of the plate material are parallel and the region in which the rolling direction and the processing direction are orthogonal are measured and averaged.
- Example 1 An aluminum alloy plate made of an A3004 material having a thickness of 0.29 mm was punched out into a circle with a general-purpose press, and simultaneously drawn to form a bottomed cylindrical body (drawing can). Then, according to the procedure shown in FIG. 3, the blank can was produced by drawing ironing. An ester synthetic oil was applied to the aluminum alloy plate before punching. In the squeezing and ironing processing, the processing was performed at a speed of about 200 to 300 spm, and wet conditions for supplying the coolant of the emulsion liquid were set.
- a diamond film is provided on the surface of a cemented carbide substrate obtained by sintering a mixture of tungsten carbide (WC) and a metal binder of cobalt, and the surface roughness Ra is 0.1 ⁇ m or less.
- a processing die was used after it was used for making at least 40,000 cans.
- the resulting blank cans are referred to as Samples 1-1 and 1-2.
- Table 1 shows the results of measuring the ratios of the samples 1-1 and 1-2 by measuring the surface roughness of the outer surface of the body part in the processing direction and the circumferential direction orthogonal to the processing direction.
- Example 2 Experimental Example 1 except that the ironing die used for drawing ironing is replaced with a die used in actual production, that is, a die made of cemented carbide after being used for making at least 40,000 cans or more.
- a blank was obtained in the same manner as above.
- the resulting blank cans are referred to as Samples 1-3 to 1-5.
- Samples 1-3 to 1-5 produced are the same as those on the market.
- Table 1 shows the results obtained by measuring the ratio of the surface roughness of the outer surface of the body portion in the processing direction and the circumferential direction perpendicular to the processing direction for the samples 1-3 to 1-5.
- the difference in surface roughness Ra when measured along the processing direction is small between the present invention and the conventional product.
- the arithmetic average roughness Ra is less than 0.030 ⁇ m in the product of the present invention. Therefore, when the ratio of the roughness between the circumferential direction and the processing direction is taken, the product of the present invention shows a high isotropy of 1.5 or less, whereas the product of the present invention has a low isotropy of more than 1.5. Yes. This is consistent with the situation of visual scratches, because the product of the present invention effectively avoided adhesion to the mold and suppressed damage to the workpiece.
- Example 5 a blank can was manufactured in the same manner as in Experimental Example 1.
- Experimental Example 6 a blank can was manufactured in the same manner as in Experimental Example 2.
- the blank can prepared in Experimental Example 5 is referred to as Sample 3-1.
- the blank cans prepared in Experimental Example 6 are referred to as Samples 3-2 and 3-3.
- Sample 3-1 is a product of the present invention, and samples 3-2 and 3-3 are conventional products.
- Table 3 shows the lightness L values and the ratios of the samples 3-1 to 3-3 measured in the processing direction and the orthogonal direction of the outer surface of the body.
- Example 7 An experiment was conducted to confirm whether or not a smooth ironing die made of a diamond film exhibits adhesion suppressing ability. Specifically, in Experimental Example 7, a blank can was manufactured in the same manner as Experimental Example 1 except that an unused ironing die was used and continuous production was performed. All the obtained blank cans are called Sample 4-1. For Sample 4-1, the surface roughness Ra was measured in the same manner as in Experimental Example 1, and the transition of the number of cans produced and the roughness of the outer surface of the body of the blank can obtained was confirmed. In Experimental Example 8, adhesion removal work was performed on the cemented carbide metal mold after it was actually used for making at least 40,000 cans, and this mold was used as in Experimental Example 7. Blank cans were continuously produced.
- Sample 4-2 All the resulting blank cans are referred to as Sample 4-2.
- Sample 4-2 the change in the number of cans produced and the roughness of the outer surface of the body of the obtained blank can were measured in the same manner as in Sample 4-1.
- Table 4 shows the arithmetic average roughness Ra1 in the orthogonal direction of the outer surface of the body and the ratio Ra1 / Ra2 of the arithmetic surface roughness between the orthogonal direction and the machining direction for Samples 4-1 to 4-2.
- the ratio is an average value of two cans obtained at random around the number of processing.
- the Ra1 value “0.020” described in the column of the number of processed 5,000 cans of the sample 4-1 is 2 cans obtained at random from the 5000 ⁇ 100 cans continuously produced in Experimental Example 7. Represents the average value.
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Abstract
Description
(1)前記加工方向に直交する方向に測定した算術平均粗さRa1が0.030μm以下である。
(2)多角度分光測色計を使用し、被加工表面での反射光をLCH法により評価したとき、加工方向および加工方向に直交する方向に45度で入射した入射光に対する正反射光を基準として、加工方向の正反射光に対して15度の角度を有する反射光の明度L15h値と加工方向に直交する方向の正反射光に対して15度の角度を有する反射光の明度L15w値との比L15w/L15hが0.7~1.3であり、且つ、前記加工方向の明度L15h値が50より大きい。
(3)アルミニウム合金製である。
(4)前記塑性加工が、しごき加工である。
(5)絞りしごき加工により得られる絞りしごきブランク缶である。
<ブランク缶の製造>
本態様のブランク缶は、主としてそれ自体公知の金属板を用いての成形加工により製造される。成形加工に供される金属板、例えばアルミニウム板は、純アルミニウムであってもよいし、アルミニウムと他の金属との合金、例えば、マグネシウムやマンガンなどを含むアルミニウム合金であってもよい。また、板材は鉄やチタン、マグネシウム等の他の金属ないし他の金属を主原料とする合金であってもよいし、ブリキ等のメッキ板でもよい。金属板は、アルミニウム合金製が好ましい。
かかる打ち抜き加工では、円板13の直径に相当する外径を有する打ち抜き用パンチ15と、素板11を保持し且つ円板13の直径に相当する開口を有するダイ17が使用される。パンチ15でダイ17上に保持された素板11を打ち抜くことにより、所定の大きさの円板13が得られる。
かかる絞り加工においては、ダイ21上に円板13が保持される。円板13の周囲はしわ押え用の治具23によって保持されている。ダイ21には、開口が形成されており、絞り用のパンチ25を用いてダイ21の開口内に円板13を押し込むことにより、絞り缶19が得られる。
上記のしごき加工用ダイ33a~33cは、加工方向下流側にいくにしたがって段階的に小径となるような形状を有しており、薄肉化が行われるようになっている。
即ち、絞り缶19は、しごき加工用パンチ43により、上述したダイ31、33a~33cを通して押し出され、さらに、しごき加工された絞り缶19の加工品の底部は、保持リング37および保持ロッド37aに押し付けられ、これにより、所定の底部の形態が賦形され、ブランク缶10が得られる。このようにしてブランク缶10が成形されると、しごき加工用パンチ43が加工方向上流側に移動し、得られたブランク缶10をガイドリング35が保持することでしごき加工用パンチ43から引き抜かれ、ブランク缶10が取り出される。
このブランク缶10は、トリミング、ネックイン加工、巻き締め加工等の後加工に付されて使用に供される。
例えば、上記のようなしごき加工は、通常下記式で定義されるしごき率が50%以下となるように、適宜の径及び数を有するしごき加工用ダイを用いて行われる。
しごき率(%)={(しごき加工前の厚み-しごき加工後の厚み)/しごき加工前の厚み}×100
例えば飲料缶製造工場で缶を連続して製造する場合では、表面が超硬合金製のしごき加工用ダイの場合、製缶速度等の条件にもよるが通常数時間ごとに凝着した金属を除去する作業が必要になる。ダイヤモンド膜であれば、作業頻度は各段に少なくなる。実際、後述の実施例に示されているように、研磨せずに同じ金型を使って連続製缶する場合、全体が超硬合金製の金型では製缶数が増えるにつれ胴部外面周方向の粗さが粗くなっていき、35,000缶以降では本発明の規定(Ra1/Ra2)を満たすブランク缶はできなかったが、ダイヤモンド膜を表面に設けた金型では、35,000缶以降でも製缶開始時の粗さと変わりがなく、最終的に160,000缶を超えても製缶開始時の粗さと変わらなかった。
ID/IG (1)
式中、
IDは、炭素膜表面のラマン分光スペクトルにおける
1333±10cm-1での最大ピーク強度であり、
IGは、炭素膜表面のラマン分光スペクトルにおける
1500±100cm-1での最大ピーク強度である、
で表される強度比が1.0以上、好ましくは1.2以上である膜が好適である。
このようなダイヤモンド膜は、ビッカース硬度が8000以上と著しく高硬度な膜であり、化学的安定性が高く、界面での被加工材との反応が抑制される。これにより、すべり性が良好となるため、過酷なしごき加工に対する耐性が極めて高い。ピーク強度比が上記範囲よりも小さいダイヤモンド膜は、グラファイト等のダイヤモンド成分以外の成分を多く含んでおり、すべり性が低く、また、しごき加工に対する耐性も低く、成形不良を生じ易い。
尚、ピーク強度比が過度に大きいと、膜が脆くなり、耐久性が損なわれる虞があるため、上記のピーク強度比は5以下であることが好ましい。
(表面粗さ)
再び図1に戻って、かくして得られる本態様のブランク缶10では、連続製缶により得られたものであっても、その胴部1の外面の周方向、即ち加工方向に直交する方向に測定した算術平均粗さRa1と、高さ方向、即ち加工方向に測定した算術平均粗さRa2との比Ra1/Ra2が0.5~1.5、好ましくは0.8~1.2と1に近い値を示す。更に、胴部1の外面の周方向算術平均粗さRa1の値は、0.030μm以下が好ましい。
尚、胴部外面に細かな縦傷が付いていると、縦傷が付いていない場合と比べて、缶高さ方向の表面粗さRa2はあまり変わらないが、周方向の表面粗さRa1の値が大きくなり、その結果、比Ra1/Ra2も大きくなる。
このように本態様のブランク缶は、連続製缶により製造されたものであっても、平滑な胴部外面を有しており、即ち、胴部外面が鏡面のようになっている。
尚、胴部外面に加工痕が付いていると、缶高さ方向の正反射率はあまり変わらないが、周方向の正反射率が低下する。
例えば、本発明の金属加工物は、金属板を圧延加工により薄肉化して得られる圧延材であってもよい。この場合、圧延ロールの回転方向が加工方向となり、圧延ロールと直接接触した面が被加工表面となる。対面する2つのロールの間に金属板を通過させて圧延する場合、圧延材の表裏両面が被加工表面となる。
また、本発明の金属加工物は、金属製の棒材を先細りの穴が開いたダイスに通して小径化することにより得られる伸線材であってもよい。
(株)東京精密製表面粗さ計(サーフコム2000SD3)を使用し、JIS-B-0601に準拠し、算術平均粗さRaを測定した。
(株)島津製作所製分光光度計UV-3100PCを用いて、缶胴部外面において、加工方向(缶胴部高さ方向)及び周方向に5度で入射した入射光に対する正反射率を測定した。尚、圧延板を原材料とする缶胴部外面には、板材の圧延方向と加工方向が平行となる領域および圧延方向と加工方向が直交する領域があるが、測定の際は、両方の領域を測定対象として平均化した。
ビデオジェット・エックスライト(株)製多角度分光測色計を使用し、アルミニウム缶の胴部外面での反射光をLCH法により評価した。具体的には、加工方向(缶胴部高さ方向)および缶胴部周方向に45度で入射した入射光に対する正反射光を基準として、加工方向15度反射光での明度L15hと直交方向15度反射光での明度L15wを測定し、比L15w/L15hを求めた。更に、同じ正反射光を基準として、加工方向30度反射光での明度L30hと直交方向30度反射光での明度L30wを測定し、比L30w/L30hを求めた。更にまた、同じ正反射光を基準として、加工方向45度反射光での明度L45hと直交方向45度反射光での明度L45wを測定し、比L45w/L45hを求めた。
正反射率の場合と同様明度の測定においても、板材の圧延方向と加工方向が平行となる領域および圧延方向と加工方向が直交する領域の両方を測定対象とし、平均化した。
汎用プレスにて、板厚0.29mmのA3004材からなるアルミニウム合金板を円形に打ち抜くと同時に絞り加工を行って有底筒状体(絞り缶)を成形した。その後、図3に示す手順に従って、絞りしごき加工によりブランク缶を作製した。打ち抜きの前にアルミニウム合金板にエステル系合成油を塗布した。絞りしごき加工においては、200~300spm程度の速度で加工を行い、また、エマルジョン液のクーラントを供給するウェット条件とした。絞りしごき加工には、タングステンカーバイド(WC)とコバルトの金属バインダーとの混合物を焼結した超硬基材の表面にダイヤモンド膜が設けられており且つ表面粗さRaが0.1μm以下であるしごき加工用ダイであって、少なくとも40,000缶以上の製缶に使用した後のダイを用いた。得られたブランク缶を、サンプル1-1および1-2とよぶ。表1に、サンプル1-1および1-2について、胴部外面の表面粗さを加工方向および加工方向に直交する周方向にそれぞれ測定して比を求めた結果を示した。
絞りしごき加工に用いるしごき加工用ダイを、実生産で用いているダイ、即ち、少なくとも40,000缶以上の製缶に使用した後の超硬合金製ダイに替えた点以外は、実験例1と同様にしてブランクを得た。得られたブランク缶をサンプル1-3~1-5と呼ぶ。作製されたサンプル1-3~1-5は市場に出回っている物と同一である。表1に1-3~1-5のサンプルについて、胴部外面の表面粗さを加工方向および加工方向に直交する周方向にそれぞれ測定して比を求めた結果を示した。
つぎに、鏡面性を評価するべく、5°正反射率を測定した。具体的には、実験例3では、実験例1と同様にしてブランク缶を製造した。実験例4では、実験例2と同様にしてブランク缶を製造した。実験例3で作成したブランク缶を、サンプル2-1と呼ぶ。実験例4で作成したブランク缶をサンプル2-2,2-3と呼ぶ。サンプル2-1は本発明品であり、サンプル2-2、2-3は従来品である。表2に2-1~2-3のサンプルについて、胴部外面の5°正反射率を加工方向および加工方向に直交する周方向にそれぞれ測定した結果を示した。
さらに、多角度分光測色計により乱反射光を測定した。具体的には、実験例5では、実験例1と同様にしてブランク缶を製造した。実験例6では、実験例2と同様にしてブランク缶を製造した。実験例5で作成したブランク缶を、サンプル3-1と呼ぶ。実験例6で作成したブランク缶をサンプル3-2,3-3と呼ぶ。サンプル3-1は本発明品であり、サンプル3-2、3-3は従来品である。表3に3-1~3-3のサンプルについて、胴部外面の加工方向および直交方向に測定した明度L値およびそれらの比を示した。
偏角度30°、45°においても、偏角度15°の場合と同様に、本発明では缶高さ方向と周方向でL値が近い値を示したが、従来品では、直交方向のL値が高かった。
表面がダイヤモンド膜からなり平滑なしごきダイスが、凝着抑制能力を発揮するか否かを確認する実験を行った。具体的には、実験例7では、未使用のしごき加工用ダイを使用する点および連続生産をする点以外は実験例1と同様にしてブランク缶を製缶した。得られたブランク缶は全てサンプル4-1と呼ぶ。サンプル4-1について、実験例1と同様にして表面粗さRaを測定し、製缶数と得られたブランク缶の胴部外面の粗さの推移を確認した。また、実験例8では、実際に少なくとも40,000缶以上の製缶に使用した後の超硬合金製金型に対して凝着除去作業を施し、かかる金型を用いて実験例7と同様にブランク缶を連続生産した。得られたブランク缶は全て、サンプル4-2と呼ぶ。サンプル4-2についても、サンプル4-1と同様にして、製缶数と得られたブランク缶の胴部外面の粗さの推移を測定した。表4にサンプル4-1~4-2について、胴部外面の直交方向の算術平均粗さRa1と、直交方向と加工方向との算術表面粗さの比Ra1/Ra2を示した。比は、任意の加工数近辺で無作為に取得した2缶の平均値である。例えば、サンプル4-1の加工数5千缶の欄に記載されているRa1の値「0.020」は、実験例7において連続生産した5000±100缶の中から無作為に取得した2缶の平均値を表している。
Claims (8)
- 塑性加工により薄肉化または小径化して得られる金属加工物において、
被加工表面の、加工方向に直交する方向に測定した算術平均粗さRa1と加工方向に測定した算術平均粗さRa2との比Ra1/Ra2が0.5~1.5であることを特徴とする金属加工物。 - 前記加工方向に直交する方向に測定した算術平均粗さRa1が0.030μm以下である、請求項1に記載の金属加工物。
- 多角度分光測色計を使用し、被加工表面での反射光をLCH法により評価したとき、加工方向および加工方向に直交する方向に45度で入射した入射光に対する正反射光を基準として、加工方向の正反射光に対して15度の角度を有する反射光の明度L15h値と加工方向に直交する方向の正反射光に対して15度の角度を有する反射光の明度L15w値との比L15w/L15hが0.7~1.3であり、且つ、前記加工方向の明度L15h値が50より大きい、請求項1に記載の金属加工物。
- アルミニウム合金製である、請求項1に記載の金属加工物。
- 前記塑性加工が、しごき加工である、請求項1に記載の金属加工物。
- 絞りしごき加工により得られる絞りしごきブランク缶である、請求項1に記載の金属加工物。
- アルミニウム合金製であり、且つ、絞りしごき加工により得られる絞りしごきブランク缶であって、
連続製缶した35,000缶以降において、胴部外面の周方向に測定した算術平均粗さRa1と胴部外面の高さ方向に測定したRa2の比Ra1/Ra2が0.5~1.5であることを特徴とする、絞りしごきブランク缶。 - 金属製の円板に絞り加工を施して得た絞り缶に、ダイヤモンド膜が設けられており且つ表面粗さRaが0.1μm以下の加工面を有するしごき加工用ダイを使用して、絞りしごき加工を施して絞りしごきブランク缶を得ることを特徴とする絞りしごきブランク缶の製造方法。
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US (1) | US11745245B2 (ja) |
EP (1) | EP3778061A4 (ja) |
JP (1) | JP7155568B2 (ja) |
CN (1) | CN111902226B (ja) |
WO (1) | WO2019188324A1 (ja) |
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JP2019166561A (ja) | 2019-10-03 |
CN111902226A (zh) | 2020-11-06 |
US20210023603A1 (en) | 2021-01-28 |
CN111902226B (zh) | 2022-09-09 |
EP3778061A4 (en) | 2021-12-29 |
JP7155568B2 (ja) | 2022-10-19 |
US11745245B2 (en) | 2023-09-05 |
BR112020019363A2 (pt) | 2020-12-29 |
EP3778061A1 (en) | 2021-02-17 |
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