Method and apparatus for embossing the inside surface of a cup-shaped article

A draw/emboss work station (18) of the invention includes emboss punch apparatus (86) moveable by a lever (340) and a hydraulic system under control of a press slide (34). Pressure sleeve apparatus (92) is slideable with respect to the emboss punch apparatus (86) and is responsive to force applied to it by the press slide (34). An emboss punch head (96) is moved downwardly into a cup-shaped article (14) to bring the article into a draw/emboss die (146) having an interior reduced diameter part (148). The emboss punch head (96) then remains stationary and spaced from the reduced diameter part a predetermined distance to define an annular opening. The pressure sleeve apparatus (92) incuding a pressure sleeve (130) is then forced downwardly into engagement with a shoulder (64) on the cup (14), and forces the cup (14) through the annular opening to thereby simultaneously draw the sidewalls of the cup (14) and transfer the design of the emboss punch head (96) to the inside surface of the cup (14).

TECHNICAL FIELD OF THE INVENTION 
The present invention relates in general to methods and apparatus for 
forming materials, and more particularly relates to the drawing of a 
planar sheet of material into a cup-shaped article, and embossing the 
inside surface thereof. 
BACKGROUND OF THE INVENTION 
In the metal forming art there are numerous ways of forming cup-shaped 
articles. One method includes pouring a molden metal into a mold to form a 
cup-like shell. Another method includes forming a cylinder of sheet metal, 
and welding a cap to one end thereof. Yet another method includes drawing 
the metal from a planar sheet of metal to form the cup-shaped article. 
While the noted methods are all effective in forming the final article, 
the latter method is the most expedient, as it is less costly and requires 
much less time. A method of forming a cup-shaped article by the latter 
noted drawing process is disclosed in U.S. Pat. No. 4,509,356, and 
assigned to the assignee hereof. 
Among other applications, cup-shaped articles are utilized in constructing 
fragmentation containers, such as employed in manufacturing military 
grenades. In this application, the inside surface of the cup-shaped 
article is embossed to form lines of weakness and thereby facilitate the 
fragmentation of the article when exploded. 
Embossing a grid pattern of grooves by techniques heretofore known in the 
art includes the forming of the pattern while the material is flat, in 
either a blank or strip form. The preferred practice is to roll form the 
material by passing it through a pair of embossing rollers, and then 
rewinding the strip in a coil for subsequent processing. One of the 
embossing rollers is machined to impress the emboss design or pattern on 
one side of the metal strip, while the other roller is a smooth surface 
used to compress the metal strip against the embossing roller. When this 
technique is employed, alloy steels which form the blank or strip material 
tend to work-harden. Work-hardening of the material is alleviated by 
annealing the strip material after the roll forming of the emboss design. 
The annealing operation is expensive, as it is necessary to heat the 
embossed material to a temperature in excess of 1,000.degree. F., under a 
controlled atmospheric condition. The embossed strip is then formed into 
the cup-shaped article by one of the methods identified above. 
Other techniques for forming a grooved structure on the inside surface of a 
bore or cylinder concerns an extrusion process which is adapted for 
forming rifling grooves within a tubular structure. Such a process is 
briefly described in the article "Extrusion of Thin-Wall Tubes Eliminates 
Machining", by William G. McEwen, P.89-90, The Tool and Manufacturing 
Engineer, December 1963. According to this process, a steel billet has a 
bore formed therethrough, and a mandrill, ram and ring die are utilized to 
extrude the billet over the mandril and thereby form the riflings. This 
process is not only expensive and time consuming, but also can be 
accomplished only on open-ended cylindrical articles. One end of the 
extruded cylinder must then be welded or otherwise capped to form the 
cup-shaped article. 
It can be seen that a need exists for a high-speed and economical method 
and apparatus for forming an embossed design on the inside surface of 
cup-shaped articles. A concomitant need exists for combining embossing and 
drawing operations of the material to facilitate the construction of the 
embossed article. An additional need exists for a high-speed drawing and 
embossing operation so that the forming is completed before work hardening 
occurs. The expensive and time-consuming annealing process can then be 
eliminated. 
SUMMARY OF THE INVENTION 
In accordance with the present invention, a method and apparatus for 
drawing a metal part and embossing the same in one operation is disclosed, 
which method and apparatus reduces or substantially eliminates the 
shortcomings and drawbacks associated with the prior art techniques. 
In accordance with the invention, an initial drawing step comprises the use 
of a draw punch and an associated draw die for forming planar metal stock 
into a preliminary cup-shaped article. The drawn cup is then transferred 
to an embossing station where the cup is subjected to a further draw 
process and a combined embossing process, in which the sidewalls of the 
cup are simultaneously drawn and embossed with a design on the inside 
surface thereof. A final draw of the embossed cup is effective to further 
shape the article and form other variations in the shape of the cup. 
According to an important feature of the invention, the embossing apparatus 
comprises a conventional punch shaft with an embossing head attached 
thereto. The emboss punch is disposed over an emboss die having a reduced 
annular part formed in the mouth of the die. A pressure sleeve surrounds 
the emboss punch for allowing the emboss punch to slide therein. The 
pressure sleeve and emboss punch operate independently to perform the 
combined draw and embossing operation. 
The embossing step is carried out by first disposing the preliminary cup 
between the emboss punch and the emboss die, and then lowering the emboss 
punch into the cup to lower it into the emboss die in engagement with the 
narrowed part. When the emboss punch is lowered a predetermined amount 
with respect to the emboss die narrowed part, an annular opening is formed 
which has a width somewhat less than that of the sidewall thickness of the 
cup-shaped article. The emboss punch is then held stationary at the 
predetermined position. Next, the pressure sleeve is forced downwardly 
over the emobss punch so that it engages the top annular rim or shoulder 
of the article, thereby forcing it through the smaller annular opening and 
impressing the emboss design of the emboss punch onto the interior 
sidewall of the article. At the same time that the design is being 
impressed on the article sidewall, such sidewall is also reduced in 
thickness due to the drawing of the material through the constricted 
annular orifice. 
In accordance with another feature of the invention, the emboss punch 
includes a replaceable emboss head so that a change from one embossing 
design to another can be quickly and efficiently made. Various emboss 
heads, including those of a spiral design, are disclosed to achieve 
different embossing patterns. When a spiral-type of embossing design is 
desired, the emboss punch is mounted in the station so as to be freely 
rotatable when the pressure sleeve forces the article through the annular 
orifice formed between the embossing punch head and the embossing die. For 
a crosshatched embossing pattern, two embossing stations are provided; one 
for embossing a spiral design in a first direction, and another for 
embossing a spiral design in a second direction to form the crosshatched 
pattern. 
The pressure sleeve and the embossing punch are independently driven by a 
common press slide which also operates the initial and final draw stations 
of the process. On the downward stroke of the press slide, a slave 
hydraulic cylinder is caused to be operated which supplies pressurized 
fluid to an emboss station cylinder. The emboss station cylinder operates 
a pivotal lever which forces the emboss punch downwardly into the cup. The 
pressure sleeve apparatus floats with respect to the emboss punch, and 
therefore is initially brought by gravity down into contact with the 
shoulder of the cup-shaped article. The continued downward movement of the 
press slide causes the hydraulic system to pivot the lever and force the 
emboss punch to the predetermined position, and thus the cup into the 
mouth of the emboss die, whereupon the lever engages with a stop. The 
emboss punch is held at this position which forms the annular opening with 
respect to the reduced diameter part of the emboss die. The continued 
downward motion of the press slide engages the pressure sleeve apparatus 
which then firmly engages the shoulder of the article and forces it 
downwardly through the annular opening. The sidewalls of the article 
thereby undergo both a drawing and an embossing of the material.

DETAILED DESCRIPTION OF THE INVENTION 
Metal Forming Work Stations 
The sequential drawing and embossing steps for forming the embossed 
cup-shaped article of the invention are illustrated in FIGS. 1a-1c. For 
convenience, FIGS. 3a-3f illustrate the article after having been 
processed in accordance with the operations of the respective work 
stations of FIGS. 1a-1c. Six basic work stations are shown for fabricating 
metal stock from a blank to an embossed cup-shaped product. However, the 
invention is not to be construed as being limited to the embossing of a 
cup-shaped article, as cylinders can also undergo the embossing operation 
of the invention. 
A first work station 10 takes circular planar sheet metal stock and forms 
the same into a preliminary cup-shaped article 14. A second draw station 
16 performs a first draw of the metal cup 14, wherein the sidewalls 
thereof are thinned. The diametric dimensions of the cup are made smaller, 
and due to the extrusion of the sidewalls, the cup is lengthen somewhat, 
axially. A second metal work station 18 shown in FIG. 1b performs a 
further draw of the cup 14, as well as a first emboss of spirals 20 in a 
first direction. The next metal work station 22 performs a third drawing 
operation on the cup 14, and also an additional emboss 24 of a spiral 
design in a second direction. The first and second emboss of the inside 
surface of the cup 14 forms a crosshatched design. A fifth metal work 
station 26 shown in FIG. 1c performs an additional draw of the metal of 
the cup 14 to shape the bottom portion thereof. A last metal work station 
28 performs a restrike operation on the cup 14, wherein the bottom or 
closed end of the cup 14 is drawn or pressed into a final shape. 
While not shown, transfer apparatus is effective to automatically transfer 
the article from one work station to another so that the cup 14 can be 
sequentially processed without handling by an operator. Essentially, the 
transfer apparatus includes spring-loaded fingers which are adapted for 
engaging the outside surface of the cup 14 and moving the cup laterally to 
a predetermined location at the next work station so that equipment 
thereat can push the cup 14 out of the spring-loaded fingers and into the 
die apparatus. Transfer feed equipment which allows parts to be 
progressively moved through a multi-station die set is well known in the 
art, and further details thereof will not be set forth in this 
description. 
In more detail, the press equipment of the invention includes a press slide 
34 which is reciprocated vertically to synchronize the operations of each 
of the work stations so that the article can be processed in an orderly 
manner and moved from one station to the next. One reciprocating stroke of 
the press slide 34 is effective to perform the necessary operations on the 
cup 14 at each work station. The press slide reciprocates at about fifty 
strokes per minute. Thus, a cup 14 can be formed into a cup, drawn, and 
embossed in about 1.2 seconds. 
The press slide 34 is moved in a reciprocating manner through a crank arm 
by a power source (not shown), as will be described in more detail below. 
Draw punches in the draw stations 10, 16, 26 and 28 are engaged by the 
press slide 34 for effecting the drawing of the metal cup 14 with 
respective cooperating draw die equipment. The combined draw and emboss 
stations 18 and 22, however, include a number of telescoping elements 
which are responsive both to the movement of the press slide 34, as well 
as other hydraulically operated equipment, to function in a timed manner 
to perform a simultaneous draw and emboss operation on the cup 14. 
A number of round metal blanks are stacked in a hopper (not shown) for 
automatic loading to the first work station 10. After the transfer feed 
mechanism selects a metal blank from the load hopper, the blank is moved 
to the first metal work station 10. Work station 10 includes a draw punch 
40 having an upper flared end 42 integral with a shaft 44. The shaft 44 is 
coupled to the press slide 34 so that when the press slide 34 
reciprocates, the shaft 44 moves accordingly. The punch 40 is integral 
with the shaft 44 and is fitted with a draw head 46. Parts 40, 42, 44, and 
46 comprise a one piece punch in stations for draw only. A housing 50 is 
guided on the punch 40 as the press slide 34 moves the punch 40 in a 
reciprocating manner. Importantly, the draw punch 40 and the transfer feed 
mechanism is constructed so that the punch 40 can move therethrough into 
the draw die mechanism located below the punch. A stripper sleeve 52 is 
fixed to a guide housing 50 for stripping the cup 14 from the punch 40 
after the cup 14 has been formed and the punch 40 is moved upwardly into 
the transfer fingers. The stripper housing 50 is connected by a trunnion 
and pin arrangement to a forked lever arm 51. The lever arm is pivoted 
somewhat to move the stripper 52 up and down. However, when the punch 40 
is moved upwardly after the forming of the cup 14, the stripper 52 is held 
stationary so that when the punch and attached cup 14 move upwardly, the 
cup is stripped off of the punch 40. 
Operating in conjunction with the draw punch apparatus of metal work 
station 10 is draw die equipment 54. The draw die equipment 54 includes a 
cylindrical draw die 56 with an upper surface 58 generated inwardly toward 
a reduced diameter section 59 where the drawing of the metal blank occurs. 
Associated with the draw die 56 is a locator block 60 which is adapted for 
fixing the draw die 56 to a stationary table (not shown), and in vertical 
registry with the draw punch 40. For further details of the cup forming 
and drawing operations, reference is made to U.S. Pat. Nos. 4,509,356 and 
4,527,413, the disclosure of which is incorporated herein by reference. As 
disclosed in the noted patents, a shoulder 64 is formed on the upper 
inside surface of the cup 14. The shoulder 64 facilitates both the drawing 
and embossing of the cup. 
Operating in conjunction with the draw die equipment 54 is article lift-out 
equipment 66. In the preferred form of the invention, the lift-out 
equipment 66 is cam operated, including a lower shaft 68 moved by a cam 
(not shown) in a timed manner to lift an upper shaft 70 upwardly, thereby 
forcing the cup 14 out of the draw die 56. The stroke of the lift-out 
equipment 66 is sufficient to lift the cup 14 upwardly and into the 
fingers of the transfer feed device. The fingers of the transfer feed 
device, being spring loaded, hold the cup 14 therein for transfer to the 
next work station. Of course, the draw punch 40 is moved upwardly 
sufficiently by the press slide 34 so that it is extracted from the cup 14 
by the stripper 52 and is free for lateral movement by the transfer feed 
mechanism. 
During the metal drawing operation, the lift-out shaft 70 remains fixed as 
shown in FIG. 1a and thereby provides a bottom for the draw die 56. 
However, little or no compression of the material forming the bottom of 
the cup 14 is had between the draw punch 40 and the lift-out shaft 70. 
Other lift-out or eject apparatus and techniques may be utilized to remove 
the cup 14 from the draw die 56. Such techniques may include steel 
springs, air springs and gas-operated springs which provide an upwardly 
directed force in a timed sequence to remove the article from the draw die 
56. 
The first draw operation in which the sidewall of the cup 14 is drawn is 
carried out to metal work station 16. Station 16 is substantially 
identical to that of work station 10, with the exception of the draw die 
72. As can be seen, draw die 72 includes a mouth 74 which is characterized 
with a taper less than that of the cup-forming die 56 of station 10. Draw 
die 72 includes an annular reduced diameter area 76 which is spaced from 
the outer surface of the draw punch head 78 so as to cause the metal 
squeezed therebetween to be thinned. As the sidewalls of the cup 14 become 
thinned due to the drawing operation, the cup becomes elongated in an 
axial direction. In comparing the cup-forming punch 40 of station 10 with 
the draw punch 80 of work station 16, it can be seen that the draw punch 
head 78 is longer than the head 46 associated with cup-forming punch 40. 
The drawing operation occurring at metal work station 16 is facilitated by 
the annular rim 82 of the punch head 78 which engages the shoulder 64 
previously formed near the edge of the cup 14 in the cup-forming station 
10. 
In accordance with an important feature of the invention, the next metal 
work stations 18 and 22 function to perform a further draw of the sidewall 
of the cup 14, as well as impress an emboss design on the interior 
sidewall surface thereof. The detailed construction of the combined draw 
and emboss stations 18 and 22 will be described below. However, it is 
sufficient to understand that the metal work station 18 includes a draw 
punch assembly 86 which is moved primarily by the motion of yoked lever 
arms 88 and 90. A pressure sleeve assembly 92 is slideable with respect to 
the punch assembly 86 and is moved independently and indirectly by the 
motion of the press slide 34. 
The emboss punch assembly 86 includes a punch shaft 94 with a replaceable 
emboss punch head 96 having a desired design 98 machined on the outer 
surface thereof. The emboss punch head 96 includes a stem 100 insertable 
into a bore formed in the lower end of the emboss punch shaft 94. 
Interference fit pins fix the punch head 96 within the punch shaft 94. 
When it is desired to form spiral-type embossing designs within the cup 14, 
the punch shaft 94 is mounted for rotational movement within a punch clamp 
holder 106. Particularly, the top of the emboss punch shaft 94 is mounted 
by a pair of thrust bearings 108 and 110 within a bearing holder 112 to an 
upper shoe die 114. While not shown in detail in FIG. 1b, a retainer plate 
116 is fixed to the shoe die 114, as well as to the punch clamp holder 
106. 
The yoked arms 88 and 90 are connected by respective pins 118 and 120 to 
respective trunnion blocks 122 and 124 which are adapted to slide in 
associated linear grooves 126 and 128 formed in opposing sides of the 
punch clamp holder 106. Thus, as the yoked arms 88 and 90 move up and 
down, the punch clamp holder 106, retainer plate 116, shoe die 114, and 
emboss punch shaft 94 move in like manner. It is also important to note 
that the yoked lever arms 88 and 90 are pivoted in a vertical manner by a 
hydraulic system (not shown) which functions in response to the movement 
of the press slide 34. 
The pressure sleeve assembly 92 comprises a pressure sleeve 130 which 
surrounds the emboss punch shaft 94. The pressure sleeve 130 includes an 
annular lower edge 132 which engages the shoulder 64 previously formed in 
the upper inside surface of the cup 14. A number of set screws fix a base 
part 136 of the pressure sleeve 130 to a pressure sleeve holder 138. The 
pressure sleeve holder 138 is generally cylindrical in nature and 
dimensioned for slideable movement within the punch clamp holder 106. The 
punch clamp holder 106 includes an inwardly beveled surface 140 at its 
bottom edge thereof functioning as a stop to prevent the pressure sleeve 
holder 138 from moving downwardly with respect to the punch clamp holder 
106 more than shown in FIG. 1b. The bottom exterior part of the pressure 
sleeve holder 138 includes an inwardly tapered surface 142 for engaging 
with the bevel 140 of the punch clamp holder 106. 
As noted above, the pressure sleeve holder 138 can slideably move with 
respect to the emboss punch assembly 86. To that end, the pressure sleeve 
holder 138 includes an upper edge 144 which is engageable with the press 
slide 34 and moved under the control thereof. While not shown, the 
pressure sleeve holder 138 includes a pair of grooves formed in opposing 
sidewalls thereof for accommodating the pins which connect the emboss 
punch shaft 94 indirectly from the upper shoe die 114 to the punch clamp 
holder 106. 
The metal work station 18 further includes a draw die 146 which includes an 
annular inside reduced diameter protuberance which functions with the 
emboss punch head 96 to simultaneously draw the sidewall material of the 
cup 14 and emboss the inside surface thereof. The draw die 146 is held 
stationary with respect to the platform by a number of fasteners (not 
shown). A lift-out mechanism 150 functions in a timed manner, similar to 
that of lift-out equipment 66 of station 10, to assist in the removal of 
the cup 14 from the draw die 146. 
The simplified operation of the draw/emboss work station 18 functions as 
follows. Reference to FIGS. 2a-2i in conjunction with FIG. 1b is made to 
facilitate the understanding of the operation performed by the draw/emboss 
station 18. The initial position of the apparatus of the invention is such 
that the press slide 34 is in its uppermost position, with the emboss 
punch assembly 86 and the pressure sleeve assembly 92 also retracted to an 
uppermost position. The transfer feed mechanism is then activated to move 
the cup 14 in a position aligned between the emboss punch head 96 and the 
emboss die 146. This is illustrated in FIG. 2a, which also shows the 
emboss punch head 96 withdrawn in the pressure sleeve 130. 
In the next step of the operation, downward movement of the press slide 34 
causes the hydraulic system to move the yoked lever arms 88 and 90 and 
move the emboss punch assembly 86 downwardly. As noted in FIG. 2b, the 
emboss punch head 96 enters the cup 14 which is held by the spring-loaded 
fingers of the transfer feed mechanism. At this point in the draw/emboss 
operation, the pressure sleeve assembly 92 is free-floating, and thus 
rides in a slideable manner with the emboss punch assembly 86. 
Accordingly, when the marginal edge 132 of the pressure sleeve 130 
contacts the shoulder 64 of the cup 14, the downward motion of the 
pressure sleeve 130 is temporarily stalled. However, the punch head 96 
continues to move into the cup 14 until the punch head 96 bottoms out 
therein. 
FIG. 2c illustrates the next position of the draw embossing step in which 
the emboss punch head 96 has forced the cup 14 downwardly out of 
engagement with the fingers of the transfer feed mechanism. Before the cup 
14 becomes completely disengaged from the transfer feed mechanism, it has 
entered the mouth of the emboss die 146, thereby remaining under 
directional control of the system. The pressure sleeve 130 continues to 
ride engaged with the cup shoulder 64 while the punch head 96 continues to 
drive the cup 14 into the emboss die 146. It should be noted that at this 
point in the operation, no drawing or embossing of the metal has yet taken 
place with regard to metal work station 18. 
FIG. 2d illustrates the position of the emboss punch head 96 which has not 
yet bottomed out in its downward travel. The emboss punch travel is shown 
stalled because hydraulic cylinder force on the lever is insufficient to 
drive the part into the emboss die 146 which is smaller in diameter than 
the part. The press slide 34 contacts the upper edge 144 and drives the 
part through the draw/emboss die 146. The emboss punch travels downward 
with the part until stops on lever halt further downward movement of 
emboss punch 96. The downward position of the emboss punch assembly 86 is 
limited by a stop mechanism (not shown) which prevents further downward 
motion of the yoked lever arms 88 and 90. In its bottom-most position, as 
shown in FIG. 2f, the corner edge 152 of the emboss punch head 96 is 
spaced a predetermined distance from the internal reduced diameter part 
148 of the emboss die 146. The distance between the emboss punch 96 and 
the reduced diameter part 148 of the emboss die defines an annular opening 
or orifice which defines a space which is smaller than the width of the 
cup sidewall. While, the emboss punch head 96 is held stationary with 
respect to the emboss die 146, it is free to rotate during the draw and 
emboss operation. The rotational feature of the punch 94 is important in 
forming spiral-type of embossing designs. 
The area of the annular space defined by the predetermined position of the 
emboss punch head 96 and the internal reduced diameter part 148 is 
calculated to equal the area of the cylindrical portion of the cup minus 
the area of the grooves 98 in the punch head, plus the area of the 
protruding embossed ridge formed on the internal surface of the cup 14. 
While not shown in FIG. 2e, the bottom corner of the cup 14 is pinched 
between the punch head corner 152 and reduced diameter die part 148, and 
thus the draw operation is started. 
Continuing with the draw/emboss operation, it should be noted that while 
the emboss punch assembly 86 remains fixed in the noted position to form 
the annular orifice, the continued downward movement of the press slide 34 
engages the top edge 144 of the pressure sleeve holder 138, whereupon the 
pressure sleeve 130 ceases to ride in a floating manner in engagement with 
the cup shoulder 64. Rather, under the force of the press slide 34, the 
pressure sleeve holder 138, and thus the pressure sleeve 130, is forced 
downwardly. As noted in FIG. 2f, the pressure sleeve 130 applies a 
downward force on the cup shoulder 64, thereby forcing the cup 14 off the 
emboss punch head 96 and forced through the annular orifice. Because of 
the reduction in the width of the cup sidewall which occurs when the cup 
14 is forced through the annular opening, the pattern of the embossing 
grooves 98 is impressed on the internal sidewall of the cup 14. The 
transfer of the emboss impression from the emboss punch head 96 to the 
internal cup sidewall occurs simultaneously with the thinning or drawing 
of the sidewall material occasioned by the cup 14 being forced through the 
annular opening. Also, when embossing a spiral design on the inside 
surface of the cup 14, the emboss punch shaft 94 and head 96 are rotated 
by the cup as its sidewall is pressed through the annular opening. 
It is important to realize that with the foregoing method and apparatus, 
the embossed design can be formed substantially over the entire interior 
surface of the vertical sidewall of the cup 14, starting at the corner of 
the cup where the bottom joins the sidewall. 
FIG. 2g depicts the cup 14 within the emboss die 146 after it has been 
fully drawn and embossed in station 18. The press slide 34 reaches the 
bottom of its stroke and its direction of movement is then reversed, 
whereupon it begins to move upwardly bringing the emboss punch head 96 
upwardly also. In response to the initial upward movement of the press 
slide 34, pressure in the hydraulic system which controls the yoked lever 
arms 88 and 90 is released, and the yoked arms are also begin to move 
upwardly. The upward movement of the yoked lever arm 88 and 90 causes the 
emboss punch assembly 86 to also move upwardly, as noted in FIG. 2g. 
However, the pressure sleeve assembly 92, not being rigidly fixed to the 
press slide 34, does not move upwardly in unison therewith, and the force 
of gravity maintains the pressure sleeve 130 engaged with the cup shoulder 
64. The cup 14 thus remains in the emboss die 146 so that the emboss punch 
head 96 can be withdrawn from the cup 14. 
With regard to FIG. 2h, as the press slide 34 continues its upward 
movement, the emboss punch assembly 86 and thus the punch clamp holder 106 
also move upwardly. The upward movement of the punch clamp holder 106 
continues until the internal beveled edge 140 comes into engagement with 
the tapered edge 142 of the pressure sleeve holder 138. Upon engagement of 
these beveled and tapered surfaces, the continued upward movement of the 
punch clamp holder 106 also lifts the pressure sleeve holder 138 upwardly. 
The emboss punch assembly 86 and the pressure sleeve assembly 92 then move 
upwardly in unison together until such elements are clear of the 
spring-loaded fingers of the transfer feed mechanism. 
FIG. 2i illustrates the final step of the combined draw/emboss operation in 
which the lift-out shaft assembly 150 forces the drawn and embossed cup 14 
upwardly out of the emboss die 146 and into engagement with the transfer 
feed mechanism. The transfer feed mechanism is then triggered so that the 
emboss cup 14 can be moved to the next metal work station. As noted from 
the foregoing sequence of steps, the combined draw and emboss step is 
carried out in one stroke of the press slide 34. Furthermore, the emboss 
apparatus is constructed to function with the apparatus used in forming 
and drawing the cup 14. 
It should be understood from the foregoing that the emboss punch head 96 
can include any of a number of emboss patterns, some of which will be 
described in more detail below. As noted in FIG. 1b, the draw/emboss 
station 18 is shown equipped with an emboss punch head 96 having a 
diagonal or spiral-type of design. In the event it is desired to emboss 
another spiral design to form a cross-hatched pattern, then a second 
draw/emboss station 22 is utilized. Such a second draw/emboss station 22 
would also be utilized to form a crosshatched, checkerboard or 
intersecting diagonal type of pattern. However, in the event only a single 
nonintersecting embossing pattern is desired, than only a single 
draw/emboss station 18 would be required. 
With regard to the second draw/emboss station 22, the emboss punch shaft 
156 is equipped with an emboss punch head 158 which includes a diagonal 
pattern 160 that is arranged opposite that of the emboss pattern 98 of the 
emboss punch assembly 86 associated with station 18. The result of the 
dual embossing stations is the cross-hatched pattern 24. In all other 
respects, the second draw/emboss station 22 is substantially identical in 
function and construction to draw/emboss station 18. 
The metal forming process of the invention includes an additional metal 
work station 26 which performs a further draw and formation of the cup 14. 
Draw station 26 is substantially identical to draw station 16, except for 
variations of the draw head 162 and the draw die 164. In essence, the draw 
operation occurring in metal work station 26 further thins the upper 
nonembossed sidewall of the cup 14, in addition to providing a desired 
shape along the bottom corner 166 of the cup 14. FIG. 3e shows the open 
end of the cup 14 reduced in diameter over that of the cup of FIG. 3d. As 
noted in FIG. 1c, the punch head 162 and draw die 164 include mating 
stepped portions which form a corresponding stepped groove around the 
bottom of the cup 14. 
Metal work station 28 is provided with draw punch equipment 168 and draw 
die apparatus 170 which performs a further draw of the open end of the cup 
14. According to this operation, the bottom of the cup 14 is also further 
formed to achieve a desired shape. 
FIGS. 3a-3f depicts the details of the cup 14 as it progresses through the 
processing of the six work stations described above. However, it should be 
understood that the number of draw stations varies with the part size and 
material, and thus those skilled in the art may utilize more or fewer work 
stations than described above. FIG. 3a illustrates a cup 172 after having 
been formed according to the operations of metal work station 10. The cup 
172 includes a cylindrical sidewall 174 and a bottom 176. Shown also is a 
shoulder 64 which is utilized in subsequent steps to facilitate the 
drawing and embossing of the cup 172. For purposes of example, the cup 172 
may include a nominal diameter of about 1.95 inches, and a nominal height 
of about 1.99 inches. 
FIG. 3b illustrates a cup 180 after having been processed according to the 
operations of metal work station 16. Due to the reduction in the outside 
and inside diameter of the cup 14 the axial length of the cup 180 is 
lengthened by about 0.27 inches and narrowed axially by about 0.23 inches. 
FIG. 3c illustrates a cup 184 after having been processed according to the 
operations of the draw/emboss work station 18. Most notably, the cup 184 
includes a diagonal design 186 on its interior surface. Due to the 
internal embossing operation, the axial length of the cup 184 is not 
extended, however the nominal diameter has been reduced about 0.07 inch. 
Again, the shoulder 64 is utilized to force the cup 184 between an annular 
opening defined by the space between the emboss punch head 96 and a 
reduced diameter part of the emboss die 146. 
FIG. 3d illustrates the result of a second emboss and draw operation 
performed according to the second draw/emboss station 22. The resultant 
embossed cup 188 includes a second spiral pattern 190 which, together with 
the previously embossed spiral pattern 186, forms a diamond-shaped pattern 
on the inside surface of the cup 188. The draw operation performed at work 
station 22 further reduces the inside and outside diameter of the cup. 
FIG. 3e illustrates a cup 194 after a draw operation performed by metal 
work station 26. The cup 194 is shown further elongated due to diametric 
reduction. The draw punch 162 and draw die 164 of station 26 are 
constructed to form a tapered transition 196 between the sidewall 195 and 
the bottom 200 of the cup 194. The embossed pattern 202 is not 
substantially affected by this draw operation. 
FIG. 3f illustrates a cup 204 formed pursuant to the operations of metal 
work station 28. As can be seen, the cup 204 includes a cylindrical 
sidewall 206 forming a major part of the cup 204, and a shorter and 
narrower sidewall section 208 formed at the bottom of the cup 204. Metal 
transition area 210 joins the major sidewall section 206 to the minor 
sidewall section 208, and metal transition area 212 joins the minor 
sidewall section 208 to the cup bottom 214. The major sidewall section 206 
of the cup 204 is not further thinned by the operation of metal work 
station 28. However, the stepped sidewall 216 is further defined by the 
work station 28 to form a cup having a desired shape. 
As noted above in connection with FIG. 1b, various embossing designs can be 
achieved by fixing to the emboss punch shaft 94 a head having the 
appropriate design. The replaceable nature of the punch head 96 enhances 
the versatility of the operation so that different embossing designs can 
be formed by simply changing the emboss punch head 96. 
Emboss Punch Heads 
FIGS. 4a-4h illustrate various embossing patterns which can be machined on 
the outer face of different emboss punch heads. Particularly, FIG. 4a 
illustrates an emboss head 220 having a symmetrical pattern of 
semicircular indentions 222 formed around the outer cylindrical surface of 
the head. The punch head 220 includes a stem 224 with a transverse linear 
groove 226 formed on opposing sides thereof for fixing the head 220 to a 
punch head shaft 94. Fixing the punch head 220 to the punch shaft in this 
manner prevents respective rotational movement between these parts. 
FIG. 4b depicts a punch head 228 which includes a symmetrical pattern of 
semicircular protrusions 230 formed on the outer cylindrical surface 232 
of the punch head 228. 
FIG. 4c shows an embossed punch head 234 which is characterized by a 
symmetrical pattern of V-shaped protrusions 236 which extend outwardly 
from the cylindrical surface 238. The V-shaped protrusions 236 spiral 
partially around the circumference of the emboss punch head 234, from one 
end to the other. Various other numbers of protrusions 236 and/or pitches 
thereof may be utilized to suit particular purposes. In order to emboss a 
crosshatch design on the inside surface of a tubular member, another 
emboss punch head (not shown) can be formed which includes outwardly 
directed protrusions similar to that of the emboss punch head 234, but 
spiraling in an opposite direction. 
FIG. 4d depicts yet another emboss punch head 240 which is characterized by 
a symmetrical pattern adapted for forming a vertically splined design. 
Particularly, the emboss punch head 240 has machined within a cylindrical 
surface 242 generally square indented areas 244. The width of the areas 
242 and 244 are substantially identical so that the raised areas and 
depressed areas impressed within the inside surfaces of a cylindrical 
article are of substantially the same width. 
FIG. 4e illustrates an emboss punch head 246 having a number of lobes 248 
each with an arcuate surface 250 beginning with a minimum distance 252 
from the axis of the emboss punch head 246 to a maximum distance 254 
therefrom. The lobes 248 are divided into quadrants around the emboss 
punch head 246, but of course, various other numbers and shapes of lobes 
can be utilized. 
FIG. 4f shows an emboss punch head 258 having an outer cylindrical surface 
260 with a number of square indented areas 262 formed therein. 
FIG. 4g illustrates yet another emboss punch head 264 having a generally 
cylindrical exterior surface 266 with smaller radius circular areas 268 
projecting therefrom. 
FIG. 4h depicts an emboss punch head 270 with V-groove indentations 272 
formed symmetrically around the outer circumference of the punch head 270. 
The emboss punch heads described above depict examples of designs which can 
be impressed within a cup. It should be understood that any of the linear 
or vertically oriented patterns could be formed in a helical or diagonal, 
or a right-hand or left-hand pattern. 
As noted above, the annular orifice formed by the space between the emboss 
punch head 96 and the emboss die 146 is related to the type of emboss 
pattern impressed on the inside surface of the cup 14. The area of the 
annular orifice is calculated to equal the area of the cylindrical portion 
of the cup after the draw, minus the area of the grooves, plus the area of 
the protuberances to be embossed. Hence, depending upon the type of emboss 
pattern utilized, the size of the emboss punch head and/or the placement 
thereof with respect to the internal reduced diameter part of the emboss 
die should be considered. 
Emboss Punch and Pressure Sleeve Assemblies 
The details of the emboss punch assembly and the pressure sleeve assembly 
are shown in more detail, in exploded form, in FIG. 5. A guide housing 
280, comprising a part of the press slide 34 shown in FIG. 1b, is also 
illustrated. The press slide guide housing 280 is cylindrical in nature, 
including an internal inwardly directed edge 282. The edge 282 includes a 
tapered surface 284 which functions as a stop that limits the downward 
movement of the emboss punch assembly 86. Also, the guide housing 280 
includes a rather large opening 286 in opposing sidewall surfaces thereof 
to accommodate the movement of apparatus which connects the yoked lever 
arms 88 and 90 to the emboss punch assembly 86. 
The emboss punch assembly 86 includes the punch clamp holder 106 connected 
by a pair of pins 288 to the upper die shoe 114. The pins 288 are press 
fit into both the punch clamp holder 106 and the upper shoe die 114 to fix 
the elements together. The retainer plate 116 is fastened to the upper 
shoe die 114 by a pair of fastening screws 292 and 294. The retainer plate 
116 does not completely cover the cylindrical opening within the punch 
clamp holder 106, but rather is constructed to define a pair of openings 
296 and 298. The emboss punch shaft 94 includes an upper end 300 which 
abuts with the undersurface of the retainer plate 116. The emboss punch 
shaft 94 is also fixed within the upper shoe die 114 by an upper thrust 
bearing 302 and a lower thrust bearing 304. With this construction, the 
emboss punch shaft 94 is free to rotate about its axial axis, but is fixed 
to the punch clamp holder 106 for following reciprocating movements 
therewith. Formed on opposing outer sidewalls of the punch clamp holder 
106 are recessed channels 306 and 308 (FIGS. 6 and 7) to accommodate the 
sliding action of a corresponding pair of trunnion slider blocks 310 and 
312. The trunnion blocks 310 and 312 are fixed to the respective yoked 
lever arms 88 and 90 by bearing pins 309 and 311. 
Continuing with FIG. 5, there is illustrated the pressure sleeve assembly 
92. The pressure sleeve assembly 92 includes the pressure sleeve holder 
138 and the pressure sleeve 130. The pressure sleeve holder 138 is 
generally cylindrical in form, including a lower end which has an external 
inwardly directed sidewall 140 which engages the internal marginal tapered 
edge 142 of the punch clamp holder 106. The pressure sleeve holder 138 
includes at its lower end thereof a bore 314 for receiving therein the 
pressure sleeve 130. A pair of threaded holes 316 are provided for 
securing the pressure sleeve 130 within the bore 314 by a pair of 
fastening screws 320. The pressure sleeve holder 138 also includes a 
smaller diameter bore 322 which is coaxially aligned with a bore 324 
formed through the pressure sleeve 130. Thus, when the pressure sleeve 130 
is fixed within the pressure sleeve holder 138, the emboss punch shaft 94 
can slide through the minor diameter bore 322 and also through the bore 
324 within the pressure sleeve holder 130. 
A pair of open-ended grooves 326 and 328 are formed in the pressure sleeve 
holder 138 for allowing movement thereof about the punch clamp holder pins 
288 and 290. The open-ended grooves 326 and 328 are formed so as to extend 
from about the middle of the pressure sleeve holder 138 to the upper end 
thereof. 
The pressure sleeve holder 138, constructed in accordance with the 
foregoing, defines a partial semicircular extension 330 and a second 
semicircular extension 332, which extend through the respective 
semicircular openings 296 and 298 located atop the emboss punch assembly 
86. The pressure sleeve holder extensions 330 and 332 are constructed with 
a length such that when the bottom tapered surface 140 of the pressure 
sleeve holder 138 engages the tapered marginal edge 142 of the punch clamp 
holder 106, the top surfaces of the pressure sleeve holder extensions 330 
and 332 extend a short distance beyond the top surface of the punch clamp 
holder 106. The diametric size of the pressure sleeve holder 138 is 
selected to be somewhat less than the internal diameter of the punch clamp 
holder 106 so as to allow free slideable movement between the elements. 
In assembling the draw/emboss station 18, the pressure sleeve holder 138 is 
inserted into the punch clamp holder 106 before the retainer plate 116, 
associated apparatus, and emboss punch shaft 94 are affixed thereto by the 
pins 288 and 290. After assembling in such manner, the pressure sleeve 
holder 138 is captured within the punch clamp holder 106, but allowed to 
move independently with respect to the punch clamp holder 106. Indeed, the 
force applied to the pressure sleeve holder 138 arises from the contact of 
the semicircular extensions 330 and 332 with the press slide 34. Thus, 
when the press slide 34 is in a raised position, the pressure sleeve 
holder 138 is not in contact with the press slide, but rather moves with 
the motion of the punch clamp holder 106 by gravity, through the 
engagement of the beveled surface 142 and the tapered surface 140. 
However, and as noted above in connection with FIG. 1b, when the bottom 
annular edge 132 of the pressure sleeve 130 becomes engaged with the 
shoulder 64 of the cup 14, the movement of the pressure sleeve holder 138 
is stalled, even though the punch clamp holder 106 continues to move the 
emboss punch head 96 further into the cup 14. 
With reference now to FIGS. 6 and 7, there is illustrated the manner in 
which the punch clamp holder 106 is moved under the force of the yoked 
lever arms 88 and 90. Vertical pivotal movement of the yoked lever arms 88 
and 90 is translated to vertical movement of the punch clamp holder 106 by 
a pair trunnion slider blocks 310 and 312. The trunnion slider blocks 310 
and 312 are mounted for slideable movement within the exterior recessed 
channels 306 and 308 of the punch clamp holder 106. Further, the trunnion 
slider blocks 310 and 312 are mounted for rotational movement about 
respective pins 309 and 311 which, in turn, are fixed within the yoked 
lever arms 88 and 90. Thus, as the ends of the lever arms 88 and 90 pivot 
about an arcuate path, the trunnion slider blocks 310 and 312 force the 
punch clamp holder 106 in a linear direction along a vertical path, while 
the slider blocks 310 and 312 move within the respective recessed channels 
306 and 308. 
It can be appreciated that the punch clamp holder 106, and thus the emboss 
punch shaft 94 and head 96 are moved in response to the movement of the 
yoked lever arms. Importantly, the pressure sleeve assembly 92 is adapted 
to float with the movements of the emboss punch assembly 86 with two 
exceptions. First, and as noted above, when the lower annular edge 132 of 
the pressure sleeve 130 initially contacts the shoulder 64 of the cup 14, 
the movement of the pressure sleeve assembly 92 is stalled. Secondly, when 
the press slide 34 moves a predetermined distance downwardly, an 
engagement therewith is made with the pressure sleeve holder extensions 
330 and 332, whereupon the pressure sleeve assembly 92 is forced 
downwardly, thereby forcing the cup 14 through the annular opening, as 
noted above. 
Draw/Emboss Work Station Operation 
FIG. 8 is a side view of the metal work station 18 which is adapted to 
perform simultaneous draw and embossing operations on the cup 14. The 
apparatus of the draw/emboss work station 18 is shown at a "top of stroke" 
sequence of the operation, in which the pressure slide 34 is at its 
uppermost position, and the forked lever arms 88 and 90 are also at their 
uppermost pivoted position. Apparatus of the draw/emboss station shown in 
FIG. 8 further includes a lever 340 which is fixed for pivotal movement by 
a pin 342 about a lever support base 344. The lever support base 344 is 
fixed with respect to the draw/emboss die holder 346. The lever 340 is 
constructed with the yoked lever arms 88 and 90, as described above. Fixed 
to the other end of the lever 340 is a bracket 348 to which a clevis 350 
is fixed. The clevis 350 is, in turn, fixed to the plunger end of a 
hydraulic cylinder 354 by a pin 352. The cylinder part of the hydraulic 
cylinder 354 is fixed by a heavy-duty bracket 356 to the lower die shoe 
358. Pressurized hydraulic fluid is supplied to the cylinder 354 by a 
high-pressure hoses 360 and 361. 
Fixed to the lever 340 is a block 362 which is engageable with the end of a 
push rod 364 which is part of a compressed gas cylinder 366. The block can 
be moved along with the lever 340 until the block 362 abuts with stop 
member 363. The gas cylinder 366 is fixed with respect to the lower die 
shoe 358, and is of the type which exerts a continuous pressure on the 
push rod 364, tending to force the push rod 364 outwardly. When the push 
rod 364 is near the bottom of its stroke, it is retracted into the 
cylinder 366. The block 362 abuts with the stop 353, thereby limiting the 
further downward movement of the yoked lever arms 88 and 90. 
Downward movement of the emboss punch assembly 86 through the lever 340 is 
effected by supplying pressurized hydraulic fluid through hose 361 to the 
hydraulic cylinder 354. The piston 351 is thereby forced outwardly and, 
through the clevis 350, the lever bracket 348 is forced upwardly. The 
lever 340 thus pivots about the pin 342 and forces the yoked lever arms 88 
and 90 downwardly. The downward movement of the yoked lever arms 88 and 90 
continues as the block 362 engages the top of the extended gas cylinder 
push rod 364, but stops when the block 362 abuts with stop member 363. The 
block 362 is adjustable with respect to the lever 340 so that the downward 
movement of the yoked lever arms 88 and 90 can be arrested at a 
predetermined position. Particularly, the block 362 is adjusted so that 
the downward movement of the yoked lever arms 88 and 90 are arrested when 
the lower portion of the emboss punch head 96 is located with respect to 
the draw/emboss die 146 so as to form the annular orifice described above. 
The rate of movement of the lever 340 is controlled by the volume of fluid 
applied to the cylinders 354. The application of fluid pressure to 
cylinder 354 is indirectly controlled by the motion of the press slide 34, 
through a hydraulic system to be discussed in more detail below. However, 
it is important to realize that once the pressure has been released from 
the hydraulic cylinder 354, the gas cylinder 366 is effective to apply an 
upward pressure to the block 362 and raise the yoked lever arms 88 and 90. 
Additional apparatus associated with the various work stations comprises 
the transfer feed mechanism 370. Forcing a part of the transfer feed 
mechanism are spring-loaded finger devices 372 and 374 for holding the cup 
14 in engagement when transferring it from one work station to another. 
The transfer feed mechanism 370 is also adapted to hold the cup 14 in a 
stationary location above the draw/emboss die 146 so that the emboss punch 
head 96 can force the cup 14 through the spring-loaded fingers 372 and 374 
and into the draw/emboss die 146. After the emboss punch has forced the 
cup 14 partially into the draw/emboss die 146 the transfer feed starts its 
return stroke, causing the spring closed fingers to open momentarily (part 
is engaged in the die and emboss punch is engaged in the part movement of 
transfer feed causes fingers to open). As the transfer feed returns to its 
starting position the pressure sleeve and emboss punch is still going 
through the working stroke and are still in the part with the part in the 
die. The returning fingers snap around the pressure sleeve and wait for 
the ejector to raise part into the fingers. Also, the spring-loaded 
fingers 372 and 374 are shaped so that when the lift-out anvil mechanism 
150 forces the cup 14 out of the draw/emboss die 146, the cup 14 can be 
forced upwardly back into engagement between the fingers 372 and 374. 
FIG. 8 further illustrates that in the "top of stroke" position, the punch 
clamp holder 106 is in its lower-most position with respect to the guide 
housing 280, and the pressure sleeve holder 138 is in its lower-most 
position with respect to the punch clamp holder 106. When positioned as 
such, the emboss punch head 96 extends downwardly, slightly beyond the 
bottom annular edge 132 of the pressure sleeve 130. 
FIG. 9 illustrates another positional arrangement of the draw/emboss 
station apparatus 18 occurring subsequent to that shown in FIG. 8. 
Specifically, FIG. 9 shows the piston 351 extended from the hydraulic 
cylinder 354, thereby pivoting the lever 340 to a position where the block 
362 is abutted against the stop member 363, and further downward movement 
thereof is prevented. It is important to understand that before the block 
362 is forced against the stop member 363, the hydraulic cylinder 354 
stalls out. However, as the pressure sleeve 92 pushes part 14 into the 
draw/emboss die 146, the force maintained in the hydraulic cylinders 
causes lever 340 to move an additional small distance and force the block 
362 in contact with stop member 363. 
When hydraulic cylinder 354 stalls out the fluid displaced by slave 
cylinder 400 is dumped over the relief 428 (FIG. 12), as will be described 
more fully below. At the position noted in FIG. 9, the emboss punch head 
96 has pushed the cup 14 out of engagement with the transfer feed 
mechanism fingers 372 and 374 and partially into the draw/emboss die 146. 
At this position, the lower annular edge of the emboss punch head 96 is 
spaced a predetermined distance from the reduced diameter part of the 
draw/emboss die 146, thereby forming the annular opening. 
During the lowering of the emboss punch assembly 86, the weight of the 
pressure sleeve assembly 92 has also allowed it to be lowered until the 
lower annular edge 132 of the pressure sleeve 130 is resting in engagement 
with the shoulder 64 of the cup 14. During the pivotal movement of the 
lever 340 occasioned by the hydraulic cylinder 354, the press slide 34 is 
also lowered. The anvil part of the guide housing 280 is shown in contact 
with the semicircular extensions 330 and 332 of the pressure sleeve holder 
138. The next sequence to be executed in the draw/emboss step is the 
forcing of the cup 14 through the annular opening by the forced downward 
movement of the pressure sleeve apparatus 92. 
FIG. 10 is another depiction of the draw/emboss station apparatus 18, 
showing the elements thereof at their lower-most positions, and with the 
draw and embossing operations fully completed on the cup 14. It can be 
seen that the movement of the lever 340 has not changed from that shown in 
FIG. 9, and thus the emboss punch head, with respect to the die 146, 
remains stationary during the emboss process. However, the press slide 34, 
and thus the guide housing anvil, have forced the pressure sleeve 
apparatus 92 downwardly. As a result, the pressure sleeve 130 applies a 
force on the shoulder 64 of the cup 14, forcing it through the annular 
orifice. Because the distance between the emboss punch head 96 and the 
reduced diameter part of the draw/emboss die 146 is somewhat smaller than 
the diameter of previously drawn cup 14, the cup material is drawn to a 
smaller nominal diameter. At the same time the embossing design of the 
emboss punch head 96 is impressed within the inside sidewall of the cup 
14. 
Also illustrated in FIG. 10 are various dimensional designations which 
identify the distances various elements of the draw/emboss station 18 
travel. Distance JJ identifies the initial movement of the emboss punch 
assembly 86 due to the operation of the hydraulic cylinder 354. Distance 
KK identifies the distance in which the die shoe 114 travels together with 
pressure sleeve 130, and pushes the cup 14 into the die 146 until halted 
by the engagement of the block 362 with the abutting stop block 363. 
Distance LL represents the combined distance of JJ and KK. Distance MM 
identifies the distance in which the pressure sleeve apparatus 92 travels 
downwardly under the force of the press slide 34. Essentially, distance MM 
represents the distance by which the cup 14 is forced through the annular 
opening. Distance identified by NN is the total free vertical movement of 
the press slide 34. 
FIG. 11 illustrates the lift-out part of the draw and embossing sequence of 
the invention. The press slide 34 is shown moved to its upper-most 
position. As noted above, the upward movement of the press slide 34 allows 
the hydraulic system to relieve the pressure applied to the hydraulic 
cylinder 354, thereby allowing the gas cylinder 366 to force the yoked 
lever arms 88 and 90 upwardly. Thus, when the press slide 34 begins its 
upward movement, the yoked lever arms 88 and 90 also move upwardly in 
unison therewith. The lift-out anvil 150 is also activated, and moved 
upwardly to force the drawn and embossed cup 14 out of the die 146 and 
back into engagement with the spring-loaded fingers 372 and 374. The 
processed cup 14 is thus ready to be transferred to the subsequent work 
station where additional drawing and/or embossing of the cup 14 may occur. 
Also, the emboss punch apparatus 86 and the pressure sleeve apparatus 92 
are in their fully raised position, ready for another cup to be moved into 
position for drawing and embossing. 
Hydraulic System 
FIG. 12 schematically depicts the hydraulic system utilized to operate the 
levers of the draw/emboss station 18 and 22. The hydraulic system of the 
invention includes a fluid reservoir 378 partially filled with oil. The 
upper part of the reservoir 378 is pressurized with air. An inlet 
connection 380 of the reservoir 378 is connected by a line to an air-check 
valve 382 and blow-off valve 384. This assures that excessive pressure 
will not be built up in the fluid reservoir 378. The inlet connection 380 
is also connected to a pressure regulator 386, and therethrough to a 
filter and water separator 388. On an inlet side of the filter and water 
separator 388, there is connected a gate valve 390 which is connected to a 
source of air pressure (not shown). 
A first outlet 392 of the fluid reservoir 378 supplies fluid pressure by a 
first, hose 394 to the piston side of a a hydraulic cylinder 354'. The 
first outlet 392 of the reservoir 378 is also connected by another hose 
398 to the piston side of the hydraulic cylinder 354. In the example, the 
hydraulic cylinder 354 is associated with the first draw/emboss station 
18, while the hydraulic cylinder 354' is associated with the second 
draw/emboss station 22. The first reservior outlet 392 is also connected 
to the piston side of a slave hydraulic cylinder 400. The slave hydraulic 
cylinder 400 is of the type having a piston 402 which is forced within the 
cylinder 400 by the application of pressure to the piston side inlet 404. 
The piston 402 is connected to a plunger 406 which separates the cylinder 
400 into a first chamber 408 and a second chamber 410. The second chamber 
410 is filled with hydraulic fluid so that when the piston 402 is forced 
downwardly, hydraulic fluid in the chamber 410 is forced through a slave 
hydraulic cylinder outlet 412. The piston 402 of the slave hydraulic 
cylinder 400 is forced downwardly in response to the downward movement of 
the press slide 34. 
A second outlet 414 of the fluid reservoir 378 is connected to a 
check-valve 416. The check-valve 416 is provided with an inlet port 418 by 
which pressurized fluid from the reservoir 378 can flow through the 
check-valve 416 and out a first outlet port 420 and a second outlet port 
422. The first outlet port 420 is connected by a hydraulic hose 424 to the 
bottom side of the draw/emboss station hydraulic cylinder 354'. The second 
outlet port 422 is connected by a hydraulic hose 426 to the bottom side of 
the draw/emboss station hydraulic cylinder 354. The second outlet port 422 
of the check-valve 416 is also connected to a relief valve 428. The relief 
valve 428 prevents excessive pressure from existing in the hydraulic line 
430 connected between the second outlet port 422 of the check-valve 416 
and the outlet 412 of the slave hydraulic cylinder 400. 
The hydraulic system of FIG. 12 operates in the following manner. When the 
press slide 34 is at its upper-most position, there is little or no 
pressure applied to the piston 402 of the slave hydraulic cylinder 400. 
Therefore, the air pressure within the fluid reservoir 378 forces 
hydraulic fluid out of the first outlet 392 and the second outlet 414. 
These pressures are substantially identical, and are applied to the upper 
and lower ends of the hydraulic cylinders 354 and 354' as well as to the 
slave hydraulic cylinder 400. However, since there is less area on the 
piston side of each of the cylinders, than on the other side, the 
respective pistons of the cylinders all tend to move upwardly. With the 
press slide 34 in its upper-most position, the piston 402 of the slave 
hydraulic cylinder is fully extended from the cylinder 400. This is not 
the case with the hydraulic cylinders 354 and 354', as the pressure in the 
gas cylinders 366 and 366' counteracts the pivotal movement of the 
respective levers 340 and 340' such that the levers do not move. As a 
result, the steady state position of the levers 340 and 340' is that shown 
in FIG. 12, i.e., pivoted in a fully clockwise direction. 
As the press slide 34 begins its downward movement, as a result of a crank 
arm rotation (not shown), the piston 402 of slave hydraulic cylinder 400 
begins to move downwardly. The check-valve 416 is then forced closed, 
thereby allowing hydraulic fluid forced out of slave hydraulic cylinder 
outlet 412 to supply high-pressure fluid to the lower connections of 
hydraulic cylinders 354 and 354'. In response to the increased hydraulic 
pressure in hoses 424 and 426, the hydraulic cylinder pistons 351 and 351' 
begin their upward movement, thereby pivoting the levers 340 and 340' in a 
counterclockwise direction. The counterclockwise rotation of levers 340 
and 340' overcomes the static pressure within the gas cylinder 366 and 
366', thus allowing the respective cylinder rods 364 and 364' to be 
retracted within the cylinders. As a result of the counterclockwise 
pivotal movement of the levers 340 and 340', the emboss punch assemblies 
86 are forced downwardly. As noted above, the downward movement of the 
emboss punch assembly 86 continues until the cup 14 is brought against the 
reduced diameter part of draw/emboss die 146 and 148. 
When further counterclockwise pivotal movement of the levers 340 and 340' 
is halted due to the stalling of the hydraulic cylinder 354 or due to the 
resistance on the blocks 362 and 362', excessive pressure is built up 
within hydraulic line 430, whereupon the relief valve 428 allows hydraulic 
fluid to be redirected into the fluid reservoir 378 via a second valve 
outlet. The operation of the relief valve 428 in response to increased 
hydraulic pressure in line 430 allows hydraulic fluid to forced out of the 
slave hydraulic cylinder chamber 410 and relieved into the reservoir 378. 
Sufficient pressure yet exists in the hydraulic hoses 424 and 426 to 
maintain the cylinder pistons 351 and 351' in extended positions. 
Once the levers 340 and 340' are pivoted counterclockwise to their stopped 
positions, the continued downward movement of the press slide 34 only 
causes a further transfer of hydraulic fluid from the slave hydraulic 
cylinder chamber 410 through the relief valve 428 to the fluid reservoir 
378. However, when the press slide 34 begins its upward movement, 
hydraulic pressure in line 430 is reduced, whereupon check-valve 416 opens 
and the pressure in the fluid reservoir 378 forces hydraulic fluid into 
line 430, thereby causing the slave hydraulic cylinder piston rod 402 to 
begin moving upwardly. As noted above, the gas cylinders 366 and 366' 
overcome the pressure in hydraulic hoses 424 and 426 and thereby force the 
levers 340 and 340' in a clockwise direction. As a result, the emboss 
punch assembly 86 begins moving upwardly. 
As can be appreciated from the hydraulic system of FIG. 12, the timed 
movement of the emboss punch assembly 86 and the pressure sleeve assembly 
92 are the result of the movement of the press slide 34. However, due to 
the unique interaction between the emboss punch assembly 86 and the 
pressure sleeve assembly 92, the movements thereof are relatively 
independent, even though occasioned by the same power source, namely the 
press slide 34. It should be understood that those skilled in the art may 
devise other hydraulic systems, or electrical systems, for achieving the 
same timed sequence to operate the metal work stations. 
FIG. 13 graphically depicts the motion of the draw/emboss station 18 
through the various sequences of the drawing and embossing operation. The 
horizontal axis of the graph represents the crank arm rotation, 
360.degree. representing a full cycle of each work station. As noted 
above, the crank arm is connected to the press slide 34, and thus a full 
rotation of the crank arm produces a full downward and return stroke of 
the press slide 34. The vertical axis of the graph represents the relative 
position of the press slide 34 during a stroke from a reference point. The 
reference point is selected, for purposes of example, to be the lower-most 
position of the press slide in its downward stroke. 
Line 432 is representative of the path taken by the feed motion. Line 434 
represents the position of the press slide 34 during different parts of 
the stroke, or rotation of the crank arm. Particularly, the position 436 
is where the press slide 34 is moving downwardly and contacts the slave 
hydraulic cylinder piston rod 402. The levers 340 and 340' begin rotating 
counterclockwise. At position 438, the pressure sleeve 130 engages the 
shoulder 84 of the cup 14. Reference character 440 indicates the position 
of the press slide 34 when the emboss punch head 96 enters the cup 14. 442 
indicates the position of the press slide 34 when the emboss punch head 96 
engages the bottom of the cup 14 and displaces the cup from the 
spring-loaded fingers 372 and 374. The cup 14 thus enters the mouth of the 
draw/emboss die 146. 
Graphical location 444 indicates that the press slide 34 is yet moving 
downwardly, causing the levers 340 and 340' to be pivoted to a 
particularly stopped position, thus pinching the cup 14 between the end of 
the emboss punch head 96 and the internal reduced diameter area of the 
draw/emboss die 146. The annular opening between the end of the emboss 
punch head 96 and the draw/emboss die 146 is thus defined. Also, relief 
valve 428 is operated, wherein hydraulic fluid from the slave hydraulic 
cylinder 400 is forced into the fluid reservoir 378. 
Reference character 446 represents the initial part of the drawing and 
embossing sequence where the pressure sleeve 130 begins forcing the cup 14 
through the annular opening between the end of the emboss punch and the 
draw/emboss die. The drawing and embossing of the cup 14 occurs during the 
motion of the press slide 34 identified between reference characters 448 
and 450. Reference character 448 identifies the press slide position where 
the emboss punch head 96 stops moving. The pressure sleeve 130 is forced 
downwardly in its stroke, thereby forcing the cup 14 through the annular 
opening. 
Reference character 450 represents the bottom of the press slide stroke 
after the crank has rotated 180.degree.. number 452 indicates the initial 
upward stroke of the press slide 34 which allows decompression of the 
slave hydraulic cylinder 400, thus allowing the gas cylinders 366 and 366' 
to force the respective levers 340 and 340' upwardly. The end of the 
emboss punch head 96 is retracted from the cup. 
Point 454 on the graph of FIG. 13 indicates that part in the upward stroke 
of the press slide 34 where the pressure sleeve 130 begins its upward 
movement, after the retraction of the end of the emboss punch head 96 from 
the cup 14. Reference character 456 is where the lift-out apparatus is 
activated to lift the cup 14 out of the draw/emboss die 146. Point 458 
indicates the upward stroke position of the press slide 34 where the 
emboss punch assembly 86 and the pressure sleeve assembly 92 halt upward 
movement in response to the full extension of the compressed gas cylinders 
366 and 366'. Point 460 represents the press slide position wherein the 
emboss punch assembly 86 and the pressure sleeve assembly 92 have been 
moved upwardly further in response to the movement of the levers 340 and 
340' occasioned by the hydraulic cylinders 354 and 354'. Lastly, 462 
indicates the time in the crank rotation in which the cup 14 is removed 
from the the draw/emboss die 146, and into the transfer feed mechanism 
370, ready for transfer to the next work station. 
From the foregoing, disclosed is a method and apparatus for forming a 
cup-shaped article and impressing a design on the inside surface thereof. 
Disclosed also is a multi-work station system for sequentially processing 
an article starting from planar sheet stock and ending with an embossed 
cup-shaped article. The sequential operations of the system comprising the 
forming, drawing and embossing steps are all synchronized and operate in a 
timed manner to provide an efficient and fast operating system. 
A principal advantage of the method and apparatus of the invention is the 
transferring of an embossed pattern from a emboss punch die head to the 
inside surface of a cup-shaped article by locating the emboss punch in a 
close relationship with an emboss die, and forcing the cup through the 
space therebetween. As a result of the constriction of the cup sidewall 
material as it passes through the opening, the emboss design is 
transferred from the emboss punch to the surface of the cup. An additional 
advantage of the method and apparatus is that the emboss punch is mounted 
for rotational movements so that spiral-type embossing patterns can be 
utilized. When impressing spiral-type embossing designs on the surfaces of 
the cup-shaped article, the emboss punch head is allowed to freely rotate 
as the sidewall material of the article is forced between the emboss punch 
and the emboss die. 
In accordance with another advantage of the invention, a pressure sleeve 
assembly is utilized as a mechanism for forcing the cup-shaped article 
through the annular opening defined by the space between the emboss punch 
and the emboss die. The emboss punch is mounted for reciprocating movement 
within the pressure sleeve, and moveable independently of the sleeve. 
Hence, the embossing operation can be carried out by inserting the emboss 
punch within the cup-shaped article and lowering the emboss punch and 
article into the emboss die a predetermined distance. When the desired 
spacing between the emboss punch and emboss die is achieved, the punch and 
die remain stationary, and the pressure sleeve is then engaged with a 
shoulder on the cup and applies a downward force to force the cup through 
the opening. The sidewalls of the cup-shaped article thus undergo a 
simultaneous draw and emboss operation. The emboss punch is then withdrawn 
from the cup, and thereafter the pressure sleeve is also withdrawn and 
moved to an initial retracted position. The embossed and drawn cup is then 
ready for movement to another metal forming work station. 
While the preferred embodiment of the method and apparatus of the invention 
have been disclosed with reference to particular emboss punch and pressure 
sleeve apparatus, it is to be understood that many changes in detail may 
be made as a matter of engineering choices without departing from the 
spirit and scope of the invention as defined by the appended claims. 
Indeed, those skilled in the art may prefer to embody the apparatus using 
electrical or mechanical equipment, rather than hydraulic equipment, and 
in light of the foregoing description, the adaption will be facilitated. 
Also, it is not necessary to adopt all of the various advantages or 
features of the present disclosure into a single composite system in order 
to realize the individual advantages. For example, with the teachings of 
the foregoing, those skilled in the art may find that an article can be 
embossed on an outside surface thereof by placing a design on the reduced 
diameter part of the die. For spiral designs, the emboss die with the 
emboss design can be made to rotate within bearings, while the punch 
remains nonrotatable.