Sheet Metal Formation - Ironing Technique Alexander Larsh Based on recent studies, advancements in the field of deep drawing and ironing have been made, which will have an effect on can manufacturing in the future. The beverage can industry has a large impact on the environment because of the hundreds of billions of cans produced annually. Many researchers are looking to make this process more cost and time effective and most importantly, more eco-friendly. One advancement that has been made is what is called the Computer Aided System, which combines the deep-drawing and ironing processes. The results of testing have shown significant improvements in the two variables analyzed, namely, total process time and total manufacturing cost. This technological approach optimizes the process for material waste and potentially lowers the environmental impact. [1] Typically, the deep drawing and ironing process requires a large amount of time, effort, and resources. Determining the form, size, type, hardness, and mechanical properties of the material being used demands multi-stage
Transcript
1. Sheet Metal Formation - Ironing Technique Alexander Larsh
Based on recent studies, advancements in the field of deep drawing
and ironing have been made, which will have an effect on can
manufacturing in the future. The beverage can industry has a large
impact on the environment because of the hundreds of billions of
cans produced annually. Many researchers are looking to make this
process more cost and time effective and most importantly, more
eco- friendly. One advancement that has been made is what is called
the Computer Aided System, which combines the deep-drawing and
ironing processes. The results of testing have shown significant
improvements in the two variables analyzed, namely, total process
time and total manufacturing cost. This technological approach
optimizes the process for material waste and potentially lowers the
environmental impact. [1] Typically, the deep drawing and ironing
process requires a large amount of time, effort, and resources.
Determining the form, size, type, hardness, and mechanical
properties of the material being used demands multi-stage analysis.
This has been found to be inefficient, and current markets require
more streamline processes to reduce costs and raise profitability.
Linking the design of the material and the manufacturing process
allows companies to manage the process from start to finish, rather
than relying on systems that require a translator to cope with the
design, and then depending on an integrator system to link up all
design and manufacturing operations during the manufacturing
process. [1, 5]
2. With the use of this state-of-the-art technology, products
can be produced faster in a more sustainable framework. The
computer-aided system has an intelligent design that allows the
user to select input data for getting the formability of material
to deep-drawing, select the process that provides the best solution
from a technological perspective to consider project cost. It can
also be used as a teaching tool, permitting students to apply their
scientific, technological, mathematical, economical, and
sustainable knowledge to gain competency in the manufacturing
environment. [1, 2] The user interface itself is shown in Figure 1
and Figure 2 below. Figure 1 shows the brass alloy that was used
for testing. Fig. 1 Input data module screen
3. Figure 2 illustrates the different variables such as
diameter, length, and thickness, among others. Fig. 2 Deep Drawing
Tool Optimization module screen Finally, Figure 3 illustrates the
flow diagram of the Computer- aided System. This diagram breaks
down each step the system goes through to produce the final
product. This technological model is structured in several modules
such as the ones pictured above that evolve gradually. (i)The Input
Data Module introduces the geometry and material characteristics of
the piece to be manufactured. (ii)The blank module calculates the
dimensions of the initial part from the input data.
4. (iii) The redrawing Module obtains the required dimensions.
(iv) The ironing Module provides a solution for the initial stages
of ironing. (v) The Optimization Module performs an optimization of
the stages of redrawing and ironing to improve the design process.
(vi) The Technological Adjustment Module adjusts the dimensions to
permit the manufacture of the tools. (vi) The Tools Module
determines the dimensions of the tools with the appropriate
tolerances of manufacturing. (viii) The Sensitivity Analysis
Modules considers the wear of the tools and defines the limiting
diameter of the dies while maintaining the stability of the
process. (ix) The Cost Analysis Module considers the raw material
cost, the work-force cost and energy cost. The results show a cost
analysis for the total number of parts being manufactured and cost
improvements obtained in the Optimization Module. (x) The Results
Module present the final results in an intuitive format showing the
evolution of different variables such as initial solution,
optimized process, and technological adjustment. [1] Improving the
durability of ironing machinery is another way researchers have
sought to make the manufacturing process more environmentally
friendly. With such a large number of cans being produced in todays
industry, having to discard machinery because of premature wear and
tear is not only costly but can be hazardous to the environment
[3]. The use of environmentally friendly lubricants Fig. 3 Flow
Diagram
5. and longer lasting machinery has been found to help the
sustainability of this industry. [7] One way to accomplish the goal
of more resilient hard wear is through the use of coating
technologies [8]. Conventional hard coatings, such as VC coating,
work well in anti-galling and anti-wear, but the friction
coefficients are particularly high under metal forming conditions,
which causes extra wear [9]. One solution could be
diamond-like-carbon (DLC), which has a low friction coefficient as
well as having high wear resistance. DLC can be applied on moving
parts and cutting tools as well as dies for sheet metal forming.
However, because of its poor adhesion to base metals, DLC can only
be applied to dies that are limited to light forming conditions
[10]. Figure 4 shows the difference in wear over time. These photos
are taken of a sliding work piece. Recent experiments conducted by
Toyota Central R&D Labs. Inc. has shown that a high adhesive
coating of DLC containing Silicon could be a solution. While this
is used primarily in the automotive industry for components such as
clutch discs, the use of it in beverage can manufacturing could be
coming soon. This would dramatically increase the life span of any
given moving mechanical part of the ironing process illustrated in
Figure 5. Fig. 4 Coating comparison
6. References [1] Ramirez, F., The development of competencies
in manufacturing engineering by means of deep-drawing tool,
Springer Science+Business Media (2011) [2]OSullivan, D., Rolstads,
A., Filos, E. (2011). Global education in manufacturing strategy.
Journal of Intelligent Manufacturing [3] Bae, J.H.a , Lee, H.W.b ,
Kim, M.S.a , Kim, C.b Optimal process planning of cng pressure
vessel by ensuring reliability and improving die life (2013)
Transactions of the Korean Society of Mechanical Engineers, A, 37
(7), pp. 865-873. [4] Kuniaki Dohdaa, Yoshinari Tsuchiyab, Kazuhiko
Kitamuraa, Hiroyuki Morib, Evaluation of tribo-characteristics of
diamond-like-carbon containing Si by metal forming simulators,
Elsevier, Wear 286287 (2012) 8491 [5] Anggono, A.D.a , Siswanto,
W.A.b Simulation of ironing process for earring reduction in sheet
metal forming (2014) Applied Mechanics and Materials, 465-466, pp.
91-95. [6] 4th International Conference on Mechanical and
Manufacturing Engineering, ICME 2013 (2014) Applied Mechanics and
Materials, 465-466, .
7. [7] H. Ike, Report on metal forming tribology research in
Japan with special focus on environmental aspects, in: Proceedings
of 2nd international conference on tribology in manufacturing
processes, vol. 1, (2004), pp. 2938. [8] H. Kim, S. Han, Q. Yan, T.
Altan, Evaluation of tools, coatings, and lubricants in forming
galvanized advanced high strength steels, (AHSS), Annals of the
CIRP Manufacturing Technology 57 (2008) 299-304 [9] F. Klocke, M.
Massmann, K. Gerxchwiler, Combination of PVD tool coatings and
biodegradable lubricants in metal forming and machining, Wear 259
(2005) 11971206. [10] M. Murakawa, S. Takeuchi, Evaluation of
tribological properties of DLC lms used in sheet metal forming
aluminium sheet, Surface and Coatings Technology 163164 (2003)
561565.