Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DIES FOR SHAPING CONTAINERS AND METHODS FOR MAKING SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[00011 This patent application claims priority to U.S. Provisional Patent
Application No.
61/600,373, filed February 17, 2012, which is incorporated herein by reference
in its entirety.
BACKGROUND
[00021 In the container industry, substantially identically shaped metal
beverage
containers are produced massively and relatively economically. In order to
expand a diameter
of a container to create a shaped container or enlarge the diameter of the
entire container, often
several operations are required using several different expansion dies to
expand each metal
container a desired amount. Also, dies have been used to neck and shape the
containers. Often
several operations are required using several different necking dies to narrow
each metal
container a desired amount.
SUMMARY
[00031 An expansion die for manufacturing metal containers comprises a
work surface
configured to expand a diameter of a metal container having a closed bottom.
The work surface
comprises a progressively expanding portion and a land. The outer diameter of
the land is a
maximum diameter of the die.
[00041 In some embodiments, a portion of the work surface of the expansion
die has a
surface finish having a maximum ratio of the closed void area in the range of
about one of 1%-
30%, 4%-26%, 10%-26%, 10%-20%, 10%-15% and 12%45%. In some embodiments, at
least
a portion of the land of the expansion die has a surface finish having a
maximum ratio of the
closed void area in the range of about one of 1%-30%, 4%-26%, 10%-26%, 10%-
20%, 10%-
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15% and 12%-I5%. In some embodiments, at least a section of the progressively
expanding
portion has a surface finish having a maximum ratio of the closed void area in
the range of
about one of 1%-30%, 4%-26%, 10%-26%, 10%-20%, 10%45% and .12%45%. The
maximum ratio of the closed void area is the closed void area/total area
measured (times 100 for
percentage).
[0905] In some embodiments, a portion of the work surface of the expansion
die,
including a portion of the progressively expanding portion and/or the land,
has a normalized
closed void volume in the range of about one of 1-2000 mm3/m2, 9-1674 mm3/m2,
33-388
mm3/m2, 100-300 mm3/m2, 100-250 mm3/m2, 125-250 mm3/m2, 150-250 mm3/m2 and 155-
231. mm3/m2. The normalized closed void volume is the closed void area times
the depth of the
area and quantifies the amount of lubricant that is able to be trapped in the
valleys of the
surface.
[0006] A progressively expanding portion has dimensions and a geometry
that when
inserted into the open end of a container works the container's sidewall to
radially expand the
container's diameter in a progressive manner as the container travels along
the work surface.
[0007] With respect to expansion dies, a land is the portion of the
working surface of an
expansion die having the largest outer diameter that contacts a section of a
container while the
die is expanding the container. It is possible for a die to have multiple
sections, each section
having a land, each land having a different outer diameter. The land having
the smaller outer
diameter travels farther into the container than the land having the larger
outer diameter. An
example of a die having multiple lands can be seen in Figure 1.
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[0008] In some embodiments, an initial portion of the work surface of the
expansion die
has geometry for forming a transition in a container from an original diameter
portion to an
expanded diameter portion. In some embodiments, the transition is stepped or
gradual,
_100091 In some embodiments the expansion die has an undercut portion,
wherein the land
is between the progressively expanding portion and the undercut portion. The
land portion has
dimensions and a geometry for setting the final diameter of the container
being formed by that
expansion die, In one embodiment, the length of the land of the expansion die
may be 0,12" or
more. In other embodiments, the length of the land of the expansion die may be
.010", .020",
0,04", 0,05, 0.08 or 0,10 or more or less. In one embodiment, the length of
the land of the
expansion die is in the range between line contact of a continuous radius to
0.01". In some
embodiments of the expansion die, an undercut portion follows the land
portion. In some
embodiments of the expansion die, the transition from the land portion to the
undercut portion is
blended.
[0010] In some embodiments, at least a portion of the undercut portion has
surface
roughness average (Ra) of about 8 itt in. to about 32 4 in. In some
embodiments, the
progressively expanding portion has a surface roughness average (Ra) of about
2 u in. to about
6 4 in. In some embodiments, at least a portion of the land of the expansion
die has surface
roughness average (Ra) of about 8 4 in, to about 32 4 in, In some embodiments,
at least a
portion of the work surface of the expansion die, including at least a portion
of the land, the
progressively expanding portion and/or the undercut portion has a surface
roughness average
measured in 3 dimensions (Sa) in the range of about 1-50 4 in, 1-48 4 in, 7-43
4 in, 20-50 4 in,
20-45 4, in, 25-45 ILL in, 30-45 4 in, 20-40 in, 30-40 4 in,
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[00111 An undercut portion comprises an undercut surface having an outer
diameter. The
outer diameter of the undercut surface is at least approximately 0.01 inches
smaller than the
outer diameter of the land portion and no less than a minimum diameter so as
to reduce but not
eliminate frictional contact between the undercut surface and the metal
container. The outer
diameter of the undercut surface is dimensioned to minimize collapse,
fracture, wrinkle and all
other physical defects, which may occur during expansion. In some embodiments,
the diameter
of the undercut surface is about 0.0075 to about 0.035 inches less than the
outer diameter of the
land portion. In other embodiments, the diameter of the undercut surface is
about 0.01, 0.02 or
0.03 inches less than the outer diameter of the land portion.
[0012] In some embodiments, the work surface of the expansion die is
dimensioned so that
when inserted into the metal container the entire land and at least a portion
of the undercut
portion enter the metal container and the land causes the diameter of at least
a portion of the
container to expand.
100131 In another embodiment, a die for narrowing a diameter of a metal
container comprises
a work surface configured to narrow a diameter of a metal container having a
closed bottom.
The work surface comprises: a neck radius portion, a shoulder radius portion
and a land, The
inner diameter of the land is a minimum diameter of the die.
[0014] In some embodiments, at least a portion of the work surface of the die
for narrowing a
diameter of a metal container has a surface finish having a maximum ratio of
the closed void
area in the range of about one of 1%-30%, 4%-26%, 10%-26%, 10%-20%, 10%-15%
and 12%-
15%. In some embodiments of the die for narrowing a diameter of a metal
container, at least a
portion of the land has a surface finish having a maximum ratio of the closed
void area in the
range of about one of 1%-30%, 4%-26%, 10%-26%, 10%-20%, 10%-15% and 12%45%. In
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some embodiments of the die for narrowing a diameter of a metal container, at
least a section of
the neck radius portion has a surface finish having a maximum ratio of the
closed void area in
the range of about one of 1%-30%, 4%-26%, 10%-26%, 10%-20%, 10%45% and 12%45%.
In some embodiments of the die for narrowing a diameter of a metal container,
at least a section
of the shoulder radius portion has a surface finish having a maximum ratio of
the closed void
area in the range of about one of 1%-30%, 4%-26%, 10%-26%, 10%-20%, 10%45% and
12%-
15%,
[0015] In some embodiments of the die for narrowing a diameter of a metal
container, a
portion of the work surface, including a portion of the neck radius portion,
the shoulder radius
portion and/or the land, has a normalized closed void volume in the range of
about one of 1-
2000 mm3/m2, 9-1674 mm3/m2, 33-388 mm3/m2, 100-300 mm3/m2, 100-250 mm3/m2, 125-
250 mm3/m2, 150-250 mm3/m2 and 155-231 mm3/m2,
[0016] With respect to a die for narrowing a diameter of a metal container,
a land is the
portion of the working surface of an expansion die having the smallest inner
diameter that
contacts a section of a container. It is possible for a die to have multiple
sections, wherein each
section has a land, each land having a different inner diameter. The land
having the larger inner
diameter travels further into the container than the land having the smaller
inner diameter,
[0017] In some embodiments, the length of the land of the die for narrowing a
diameter of a
metal container is between about 0.02" to about 0.08". In other embodiments,
the length of the
land of the die for narrowing a diameter of a metal container is about 0.03"
to about 0,07". In
yet other embodiments, the length of the land of the die for narrowing a
diameter of a metal
container is between about 0.04" to about 0.06". In one embodiment, the length
of the land of
the die for narrowing a diameter of a metal container is about 0,04". In one
embodiment, the
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length of the land of the die for narrowing a diameter of a metal container is
in the range
between line contact of a continuous radius to 0.01".
[0018] A neck radius portion is a portion of the necking die that forms a
radius on the
container immediately adjacent to a neck or the portion of the container
having its diameter
narrowed by a land of the die.
[0019] A shoulder radius portion is a portion of a necking die that forms a
radius on the
container being narrowed adjacent to a neck radius.
[0020] In some embodiments of the die for narrowing a diameter of a metal
container, the die
has a relief, wherein the land is between the neck radius portion and relief.
In some
embodiments of the die for narrowing a diameter of a metal container, the
transition between the
land and the relief is blended. In some embodiments, at least a portion of the
relief has surface
roughness average (Ra) of about 8 in. to about 32 la in. In some
embodiments, at least a
section of the shoulder radius portion has a surface roughness average (Ra) of
about 2 la in. to
about 6 IA in. In some embodiments, at least a section of the neck radius
portion has a surface
roughness average (Ra) of about 2 in, to about 6 in, In some embodiments,
at least a portion
of the land has surface roughness average (Ra) of about 8 IA in. to about 32
IA in, In some
embodiments, at least a portion of the work surface, including at least a
portion of the land, the
shoulder radius portion, neck radius portion and/or the relief has a surface
roughness average
measured in 3 dimensions (Sa) in the range of about 1-50 in, 1-48 in, 7-43
in, 20-50 in,
20-45 in, 25-45 in, 30-45 in, 20-401..L in, 30-40
100211 The dimensions of the relief are provided to reduce frictional
contact with the metal
container and the necking die, once the metal container has been necked
through the land and
knockout, Therefore, in some embodiments, the relief in conjunction with the
Ra of the necking
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surface contributes to the reduction of frictional contact between the necking
die wall and the
metal container being necked, wherein the reduced frictional contact maintains
necking
performance while reducing the incidence of collapse and improving stripping
of the metal
container. In one embodiment, the relief extends into the necking die wall by
at least 0.005
inches measured from the base of the land. The relief may extend along the
necking direction
(along the y-axis) the entire length of the top portion of the metal container
that enters the
necking die to reduce the frictional engagement between the metal container
and the necking die
wall to reduce the incidence of collapse yet maintain necking performance. The
relief comprises
a relief surface, wherein an inner diameter of the relief surface is at least
about 0.01 inches
greater than the inner diameter of the land portion and an inner diameter of
the relief surface is
no greater than a maximum diameter so as to reduce but not eliminate
frictional contact between
the sidewall of the metal container and the relief surface while maintaining
necking performance
when necking the sidewall of the metal container. In some embodiments, the
diameter of the
relief surface is about 0,0075 to about 0.035 inches greater than the inner
diameter of the land
portion. In other embodiments, the diameter of the relief surface is about
0.01, 0.02 or 0.03
inches greater than the inner diameter of the land portion.
[0022] In some embodiments, the work surface is dimensioned so that when
inserted into the
metal container the entire land and at least a portion of the relief travel
relative to the container
in an axial direction and at least a portion of the relief travels beyond a
top of the container.
[0023] In another embodiment, an expansion die for manufacturing metal
containers
comprises a work surface configured to expand a diameter of a metal container
having a closed
bottom. The work surface comprises a progressively expanding portion; and a
land, An outer
diameter of the land is a maximum diameter of the die. When the expansion die
is expanding a
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metal container, at least a portion of the work surface has a surface having a
ratio of area in
contact with the metal container to area not in contact with the metal
container in the range of
about one of 25-99%, 30-71%, 41-71%, 40-55%, 40-52%, 35-55% and 30-60%. In
some
embodiments, the expansion die of this paragraph has the same characteristics
of the expansion
die(s) described above.
[0024] In another embodiment a die for manufacturing metal containers
comprises a work
surface configured to narrow a diameter of a metal container having a closed
bottom. The work
surface comprises: a neck radius portion, a shoulder radius portion and a
land. An inner
diameter of the land is a minimum diameter of the die. When the die is
narrowing the metal
container, at least a portion of the work surface has a surface having a ratio
of area in contact
with the metal container to area not in contact with the metal container in
the range of about one
of 25-99%, 30-71%, 41-71%, 40-55%, 40-52%, 35-55% and 30-60%.
[0025] In another embodiment, a method of manufacturing a die for shaping
metal containers
comprises: providing an expansion die for manufacturing metal containers
comprising a work
surface configured to expand a diameter of a metal container having a closed
bottom; and
peening at least a portion of the work surface. The work surface comprises a
progressively
expanding portion and a land. An outer diameter of the land is a maximum
diameter of the die.
[0026] In some embodiments, at least a portion of the land is peened. In
some embodiments,
at least a portion of the progressively expanding portion is peened.
[0027] In some embodiments, the work surface is peened with precision balls
having a
diameter in the range or about one of 1/16th in-3/32th in and 1/16th in-5/32th
in.
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[0028] In
some embodiments, the peened portion of the work surface has a surface finish
having a maximum ratio of the closed void area in the range of about one of 1%-
30%, 4%-26%,
10%-26%, 10%-20%, 10%-15% and 12%-15%.
[0029] In
some embodiments, the peened portion of the work surface has a ratio of area
in
contact with the metal container to area not in contact with the metal
container in the range of
about one of 25-99%, 30-71%, 41-71%, 40-55%, 40-52%, 35-55% and 30-60%. In
some
embodiments the percent of area of the working surface that is peened is about
one of 50-100%,
71-76%, 68-78%, 50-80%, 60-80% and 60-70%, In some embodiments, air pressure
used to
thrust the precision balls while peening the die surface is in the range of
about one of 10-30 psi,
15-20 psi, 10-20 psi and 15-30 psi,
100301 In another embodiment, a method of manufacturing a die for shaping
metal containers
comprises: providing a die for manufacturing metal containers comprising a
work surface
configured to narrow a diameter of a metal container having a closed bottom;
and peening at
least a portion of the work surface. The work surface comprises: a neck radius
portion, a
shoulder radius portion and a land. An inner diameter of the land is a minimum
diameter of the
die. In some embodiments, at least a portion of the land is peened. In some
embodiments, at
least a portion of the shoulder radius portion is peened. In some embodiments,
at least a portion
of the neck radius portion is peened. In some embodiments, the work surface is
peened with
precision balls having a diameter in the range of about one of 1/16th in-
3/32th in and 1/16th in-
5/32th in. In some embodiments, the peened portion of the work surface has a
surface finish
having a maximum ratio of the closed void area in the range of about one of 1%-
30%, 4%-26%,
10%-26%, 10%-20%, 10%-15% and 12%-15%. In some embodiments, the peened portion
of
the work surface has a ratio of area in contact with the metal container to
area not in contact
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with the metal container in the range of about one of 25-99%, 30-71%, 41-71%,
40-55%, 40-
52%, 35-55% and 30-60%. In some embodiments the percent of area of the working
surface
that is peened is about one of 50-100%, 71-76%, 68-78%, 50-80%, 60-80% and 60-
70%. In
some embodiments, the air pressure used to thrust the precision balls while
peening the die
surface is in the range of about one of 10-30 psi, 15-20 psi, 10-20 psi and 15-
30 psi.
[0031] All of the above embodiments are able to be used when narrowing or
expanding a
metal container without the use of lubricant. All of the above embodiments are
suitable for use
on any type of metal container including drawn and ironed aluminum containers
having a
closed, integral bottom, aka a two-piece container. In all of the embodiments
above, the metal
comprising the metal container may be any metal known in the art including,
but not limited to,
aluminum and steel. The metal container may or may not have a dome. In some
embodiments,
the metal container is a one-piece metal container having a closed bottom. In
some
embodiments, the metal container is comprised of multiple pieces of metal
seamed together.
[0032] A surface finish having a maximum ratio of the closed void area in
the range of about
one of 1%-30%, 4%-26%, 10%-26%, 10%-20%, 10%-15% and 12%-15% will be referred
to as
a "textured surface" herein. The open void volume and closed void volume are
as characterized
by WinSam (Surface Analysis Module for Windows) as described in ("Surface
Characterisation
in Forming Processes by Functional 3D Parameters," S. Weidel, U. Engel, Int.
J. Adv. Manuf.
Technol, (2007) 33: 130-136), which is incorporated herein by reference.
[0033] In one embodiment, the textured surface is created on the necking
and expansion dies
via peening with precision ball bearings to create a smooth, but dimpled,
texture. Peening
comprises thrusting precision balls with hardness greater than the die to
create dimples in the
tool surface. The design of the finished surface relies on the size and
hardness of the balls, the
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velocity of the blast process, and the number of repeat hits against the die.
For the purposes of
this specification, a precision ball is a ball having a diameter that varies
by no more than about
1%.
[0034] A tool surface that is smooth, but not flat, is able to reduce
friction without excessive
debris generation or tool wear. The reduced friction is due to reduced area of
contact between
the die and the metal container. Contact area is as characterized by WinSam
(Surface Analysis
Module for Windows) as described in ("Surface Characterisation in Forming
Processes by
Functional 3D Parameters,", S. Weidel, U. Engel, Int. J. Adv. Manuf. Technol.
(2007) 33: 130-
136), which is incorporated herein by reference. The reduced friction enables
metal containers
to be expanded or narrowed to a greater degree in a single stroke of an
expansion die or a
necking die without damaging the container. Damage includes wrinkling,
fracturing, ludering,
collapse of the metal container or anything that diminishes the appearance of
the metal
container.
[0935] Some embodiments of this invention look at topography of the
textured surface using
3-dimensional surface parameters and aim to minimize the area of contact of
the tool with the
work-piece.
[0036] In some embodiments, use of a textured surface on an expansion or
necking die may
have any combination of the following advantages: maximizing the extent of
metal forming in a
single stroke of an expansion or necking die without damaging the container
due to decrease in
friction, thus reducing the number of metal forming steps and reducing the
amount of scrap;
reducing the starting weight required to meet final product dimension
specifications; eliminating
the need to use lubricant when forming the metal containers. In some
embodiments, peening a
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die with precision balls results in a die that can form a metal container
without defects more
consistently than a highly polished die.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Figure 1 depicts a cross-section of an expansion die having two
lands;
[0038] Figure 2 is depicts a partial cross-section of the expansion die of
Figure 1;
[0039] Figure 3 depicts a cross-section of a die for narrowing a diameter
of a metal
container;
[0040] Figure 4 illustrates the direction of metal flow;
[0041] Figure 5 shows the inside diameter of a portion of the working
surface of the necking
die after it has been peened as described above;
[0042] Figure 6 includes small field of vision images of the inside
diameter of a portion of
the working surface of the necking die shown in Figure 5;
[0043] Figure 7 shows the surface topography of a ground surface;
[0044] Figure 8 is a chart showing the average transverse Ra of the both
the peened surface
and the ground surface shown in Figures 5-7;
100451 Figure 9 shows the surface topography of the peened working surface of
an expansion
die;
100461 Figure 10 shows the surface topography shown in Figure 9 with
corresponding line
profiles showing the depth and height of indentations;
[0047] Figure 11 shows the bearing area curve of the peened working surface
shown in
Figures 9 and 10;
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[0048] Figure 12 shows the amount of forming load an expansion die having a
peened
working surface placed on a metal container during expansion of the container;
[0049] Figure 13 shows forming energy of an expansion die having a peened
working
surface;
[0050] Figure 14 shows energy due to friction versus surface bearing area
with respect to the
non-peened surface; and
[0051] Figure 15 shows energy due to friction versus surface bearing area
with respect to the
peened surface.
DESCRIPTION
[0052] An exemplary expansion die 10 is shown in Figures 1 and 2. A work
surface 12
comprising a progressively expanding portion 14 and a land 16 is shown, An
undercut 18 is also
illustrated.
[0053] An exemplary die 30 having a work surface 32 configured to narrow a
diameter of a
metal container is shown in Figure 3. The work surface has a neck radius
portion 34, a shoulder
radius portion 36 and a land 38. A relief 40 is also shown,
[0054] In one example, the work surface of a necking die was peened with
0,093" diameter
Class 1000 balls. The quality of the balls was sufficient to minimize dust
generation or fracture
of the balls. An analysis of the peened necking die follows,
= The inside diameter of the necking die was processed using a right angle
lance
= A replica of the inside diameter of the necking die was taken at one end
= Topography and roughness data is from the replica
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= All topography images from replicas have been inverted to depict the true
topography
of the die surface
= Definitions
o Sci is the Core Fluid retention index, Sci>1 indicates good fluid
retention.
o Svi is the Valley Fluid retention index. 0<Svi<0.2 with high Sci
indicates good
fluid retention in the valley areas,
o Vel is the closed void volume indicating the void volume at the surface
available
to trap fluids
o Vop is the open void volume indicating the void volume at the surface
that allows
fluid to escape
= Instruments
- Topography ¨ NanoFocus uSurf I
= Using a 20X objective giving a field of view (FOV) of 0.8mm X
0.8mm.
= Large field of view (LFOV) topography 5.5mm X 2.15mm
[0055] Figure 4 illustrates the direction of metal flow in relationship to
the following
topographic images.
[0056] Figure 5 shows the inside diameter of a portion of the working
surface of the necking
die after it has been peened as described above.
[0057] Figure 6 includes small field of vision images of the inside
diameter of a portion of
the working surface of the necking die shown in Figure 5.
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[0058] Surface characteristics of the working surface of the necking die
after peening were
as follows: Sa avg=18.8pin; Sci avg=1.63; Svi avg=0.11; Vol avg=72.2 mm3/m2;
Vop
avg-1965 mm3/m2.
[00591 Figure 7 shows a ground, not peened surface. Surface characteristics
of the surface
shown in Figure 7 were as follows: Sa avg=20.54in; Sci avg=1.24; Svi avg=0.16;
Vet avg=46.6
mm3/m2; Vop avg=2640 mm3/m2.
[0060] Figure 8 is a chart showing the average transverse Ra of the both
the peened surface
and the ground surface.
Conclusions
= The peened surface had almost twice the closed void volume as a ground
surface with
similar Ra values
= The fluid retention parameters Sci, and ISvi both indicate the surface on
the peened
necking die has much better fluid retention than a ground surface
= The closed void volume Vel, and open void volume Vop parameters also
shows the
fluid retention to be good for the peened surface on the necking die
= This indicates the peened surface would have much better tribologieal
performance
than a ground surface.
[0061] In another example, an expansion die was peened with 0.1575" (4 mm)
Class 1000
balls,
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[0062] Figures 9 and 10 show the surface topography of a portion of the
working surface
after peening. Figure 11 shows the bearing area curve of the peened portion of
the working
surface.
[0063] In another example, the working surfaces of several expansion dies
were modified by
peening and the resulting effects on friction were compared to a baseline
friction from a die
surface that has been hard turned and lightly polished. The hard turned and
lightly polished
surface is not textured but has an Ra value of 8 to 10 Din. All other factors
were held constant
(Pre-Form, Tool Geometry, no air stripping used, no lubrication used). 10
samples were taken
for each surface combination. A "B Ball" is a precision ball having 1/16th
inch diameter. A "C
Ball" is a precision ball having a 3/32 inch diameter.
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Pre-Form Tool
Working Surface Lubricant
(Constant) (Constant)
Hard turned and lightly
polished (HT&P)
1/16th Precision Ball
Peen on top of Hard
'rp-i,
,_al
turned and lightly tv) ,,zJ 0 V)
..
0
polished (HT&P to 'B') ,-t4
0 ra,
ri) o
.E 0
.,-.
C Ball re-peened on g c)
C=1 6
U GO
,-0 N. A 0
..
top of 'B' Ball Peened
g
CI 'fi -o
0 sa,
Z 0 li x
tool as described ('B' o LQ
o
Ball to 'C' Ball)
H 0
3/32h6 Precision Ball
'-
Peen on top of Hard
turned and lightly
polished (HT&P to 'C')
[0064] Changes in friction due to tool surface were evident from changes in
Forming Energy.
Forming Energy totals were calculated from Load vs. Displacement data using a
numerical
integration technique,
[0065] Tool surfaces were characterized by Sa (3-D parameter for Surface
Roughness), Vol
(Normalized Closed Void Volume), aclm (Maximum Ratio of the Closed Void
Area(/total area
measured)) and percent contact area for each surface finish.
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[0066] Strain Energy was calculated using Finite Element Analysis using the
given Tool and
Pre-Form Sample Geometry to provide Forming Energy in a frictionless state.
Friction data was
then tabulated by subtracting the Strain Energy from the Forming Energy totals
to arrive at
Energy figures due to Friction.
[0067] Results are provided with a Percent Change in Friction Energy for
each surface
characterized in percent contact area.
[0068] Figure 12 shows the amount of forming load the expansion die placed
on the metal
container. Figure 13 shows forming energy. Figure 14 shows energy due to
friction versus
surface bearing area with respect to the non-peened surface. Figure 15 shows
energy due to
friction versus surface bearing area with respect to the peened surface.
Forming Energy Comparison
No Lubrication / 2.625 inches of Travel
Tool Surface Level Number of Mean Std Dev Connecting
Runs (inlbs) (inlbs) Letters
HT&P 10 1139 17.1 A
HT&P to 'B' Ball 10 1062 20.1
HT&P to 'C' Ball 10 945 14.8*
'B' Ball to 'C' Ball 10 978 16.5
* Standard deviation calculation excludes open circled outlier from Forming
Energy data.
= Adding the 'C' ball finish on top of an original hard turned and lightly
polished tool
surface was shown to reduce Forming Energy by 15 to 19 percent with no use of
lubricant.
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= Using a smaller diameter ball ('B' Ball) was shown to reduce Forming
Energy by 4 to 10
percent with no use of lubricant.
= Re-peening the B' Ball surface created above with the 'C' Ball did not
produce a
statistically significant change in Forming Energy.
[0069] For the purposes of this specification, terms such as top, bottom,
below, above, under,
over, etc. are relative to the position of a finished metal container resting
on a flat surface,
regardless of the orientation of the metal container during manufacturing or
forming steps or
processes. A finished metal container is a metal container that will not
undergo additional
forming steps before it is used by an end consumer. In some embodiments, the
top of the
container has an opening.
[0070] Although the present invention has been described in considerable
detail with
reference to certain versions thereof, other versions are possible. Therefore,
the spirit and scope
of the appended claims should not be limited to the description of the
versions contained herein.
[0071] All features disclosed in the specification, including the claims,
abstracts, and
drawings, and all the steps in any method or process disclosed, may be
combined in any
combination, except combinations where at least some of such features and/or
steps are
mutually exclusive. Each feature disclosed in the specification, including the
claims, abstract,
and drawings, can be replaced by alternative features serving the same,
equivalent or similar
purpose, unless expressly stated otherwise. Thus, unless expressly stated
otherwise, each feature
disclosed is one example only of a generic series of equivalent or similar
features.
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[0072] Any element in a claim that does not explicitly state "means' for
performing a
specified function or "step" for performing a specified function should not be
interpreted as a
"means or step for clause as specified in 35 U.S.C. 112.
