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NEW MANUFACTURING PROCESSES FOR THIN WALLED COMPONENTS

Objective


The tests carried out using the equipment developed in the prject showed that:-



(a) cans with a midwall thickness down to 30mm could be manufactured by rolling using a single rotary forming head.



(b) using a single axis forming machine production rates of 1 can per 1.4 seconds could be achieved



(c) cans with a top wall thickness down to 120mm could be necked and flanged and end closured could be attached to the thin walled cans

The proposed research is directed at developing the key elements of a preproduction prototype process for thin walled components. A new incremental metal forming process based on roller burnishing will be at the heart of the technology, in addition, non-circular starting blanks will be used for the produ tion of components. The aim is that these major process innovations will allow significant reductions in the amount of raw material used in the manufacture of a wide variety of components from steel and aluminium. This will be achieved both by reducing the amount of material scrapped during the process and by reducing the amount of material in the produ ct itself. The major research tasks are:

1. Development of a square blank deep drawing tool

2. The development of a basic (stationary) forming head capable of reducing the wall thickness of drawn and ironed cans.

3. The use of the basic forming head to reduce the wall thickness of redrawn cans.

4. The development of a high speed (rotating) forming head.

5. Construction of an actuated high speed forming head.

6. Construction of a fully instrumented, single axis, pre-production can forming machine

Successful completion should yield savings in materials of between 19%-25%.

Coordinator

DANISH TECHNOLOGICAL INSTITUTE
Address
Gregersensvej,p.o.box 141
2630 Taastrup
Denmark

Participants (5)

BRUEEL & KJAER A/S
Denmark
Address
Skodsborgvej 307
2850 Naerum
CMB Packaging Technology plc
United Kingdom
Address
Downs View Road
OX12 9SP Wantage
HOOGOVENS IJMUIDEN BV
Netherlands
Address
P.o. Box 10.000 Kesslerplein 1
1970 CA Ijmuiden
Loughborough University of Technology
United Kingdom
Address
Ashby Road
LE11 3TU Loughborough
WILHELM HEGENSCHEIDT GmbH
Germany
Address
Hans-heinrich-warnke-straße 8
3100 Celle