1. 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. 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. 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. 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. 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. 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. [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.