Thinning Minimization for Forming Aluminum Beverage Can End Shells

Abstract

Forming simulations of the can end shell have been implemented based on both of the axisymmetric model and three-dimensional models, for a better understanding of the forming process. The comparison shows that the simulation results agree reasonably well with the experimental observations of the actual forming process. The influence of the loads applied to tools, the clearance between tools, the shape of the tool profile and the position of tools have been investigated, based on the axisymmetric model to save computational time. The design optimization method based on the numerical simulations have been applied to search the optimum design points, in order to reduce the thinning subjected to the constraints of the geometric shape of the shell and the suppression of wrinkles. The optimization results show that the thinning can be improved up to 4% by optimizing the forming route, adjusting the clearance and the load, and modifying the tool shape. NomenclatureH 1 = Unit depth of the shell H 2 = Lip height of the shell H 3 = Panel depth of the shell P 1 = load applied to the upper piston P 2 = load applied to the die center P 3 = load applied to the lower piston P 4 = load applied to the panel punch E = Young's modulus of the blank ν = Poisson's ratio of the blank σ 0 = yielding stress of the blank T 0 = initial thickness of the blank before forming T min = minimum thickness of the shell after forming ε 0 = minimum circumferential plastic strain of the shell= rate of change in the load applied to the panel punch

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