Patent Description:
Metal sheets can be stamped or drawn to form the metal sheets into desirable shapes suitable for various applications. A lubricant or forming fluid may be used to reduce friction and control the flow of material during the forming process. The lubricant or forming fluid may be used as a coolant, since the metal may heat during the forming process. A variety of lubricants or forming fluids are available, and different formulations may be suitable for different forming processes or for the resultant formed product. For example, some water-based lubricants may be easy to remove or leave little residue after cleaning but may not provide sufficient lubrication for some forming processes. Conversely, some oil-based lubricants may provide suitable levels of lubrication and good cooling capabilities, but may leave a residue or be difficult to remove from the formed metal surface, limiting their use for some formed products. In high rate manufacturing processes, improper forming can sometimes result in damaged metal products which can jam the forming equipment, resulting in costly down time.

Beverage containers are commonly made using such high rate manufacturing processes. As an example, the process of making conventional beverage containers generally includes making a blank out of metal material, such as aluminum. The blank may be drawn into a shallow cup and redrawn to reduce the diameter and deepen the cup. The cup may be ironed to reduce the wall thickness of the cup by driving the metal material through one or more ironing dies using a punch or ram. Existing ironing dies can create excessive friction between the cup sidewalls and the die, causing the cup walls to tear or otherwise weaken. Additionally, the excessive friction may dislodge metal particulate from the cup, which can build up on the die, leading to frequent die cleaning or replacement. Prior art document <CIT> discloses a system and a method for metal forming using a punch, a die and a current source, wherein a current is applied between the punch and the die and through the metal during forming in order to improve the formability of the metal. The document mentions lubrication to prevent the wear of the molding apparatus, to improve the processing precision of the molded product and to prevent breakage, but gives no details concerning the lubricants and/or concerning possible effects of the current to the lubricants. The system of <CIT> is a system with the features of the preamble part of the independent system claim. In the article titled "<NPL>, a system and a method for vibration assisted metal forming are described, in particular for producing cans and cups. Both <CIT> and <CIT> describe a method with the features of the preamble part of claim <NUM>, wherein in those two documents, the same lubricant is used on the die side and on the punch side of the sheet metal blank. <CIT> discloses an ultrasonic vibration-assisted deep-drawing mold and a corresponding method of operating the mold, wherein the ultrasonic actuator is coupled to the punch.

The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

The invention proposes a method with the features of claim <NUM> and a system with the features of claim <NUM> for making metal products such as aluminum alloy products, like beverage containers and other products. The method of the invention employs a technique where friction between a metal product and stamping or drawing equipment, such as a punch, die, or stamp, are modified to improve the forming operation. An electric current is applied to or through a lubricant used during a stamping or punching process to modify a friction coefficient between the metal product and the stamping surface. By applying a suitable current to or through the lubricant, the stamping or punching process can be optimized to increase stamping or punching performance and removal or ejection of the formed metal product from the stamping or punching equipment. In another aspect not pertaining to the invention, ultrasonic vibrations can be applied to parts of the stamping or drawing equipment, or the metal product, to modify frictional forces.

The method of making a metal product according to the invention comprises applying a first lubricant on a punch side of a sheet metal blank; applying a second lubricant on a die side of the sheet metal blank; drawing the sheet metal blank using a punch and a die to form the sheet metal blank into a metal product while controlling one or both of a first coefficient of friction between the punch side of the sheet metal blank or a second coefficient of friction between the die side of the sheet metal blank and the die such that the first coefficient of friction is greater than the second coefficient of friction; and ejecting the metal product from the die while controlling a third coefficient of friction between the metal product and the punch to be less than the first coefficient of friction. Although application of lubricants onto the surface of a sheet metal blank is noted above, this may include applying the lubricant onto the corresponding surface of the punch or die instead of applying the lubricant directly to the sheet metal blank.

As the first coefficient of friction is greater than the second coefficient of friction in a relative sense, controlling the first coefficient of friction comprises applying a first electric current through the first lubricant or applying the first electric current through the second lubricant. The coefficient of friction between the metal product and the punch is a useful aspect for minimizing ejection problems, so controlling the third coefficient of friction comprises applying a second electric current through the first lubricant.

Example magnitudes of the first electric current or the second electric current, or both, may independently be from about <NUM> mA to about <NUM> A, such as from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> mA, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> mA to <NUM> A, from <NUM> A to <NUM> A, from <NUM> A to <NUM> A, or from <NUM> A to <NUM> A. In some cases, the first electric current or the second electric current, but not both, has a magnitude of <NUM> A. Example voltages for applying the first electric current or the second electric current, or both, independently may be from about <NUM> V to about <NUM> V, such as from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, from <NUM> V to <NUM> V, or from <NUM> V to <NUM> V.

The first electric current and the second electric current applied to the first lubricant may be applied in any convenient manner. For example, the first electric current may applied between the punch and the die. The first electric current may be applied between the punch and the sheet metal blank. The second electric current may be applied between the punch and the die or between the punch and the metal product. The first electric current may flow from the punch to the die through at least the first lubricant. The first electric current may flow from the die to the punch through at least the first lubricant. The first electric current may flow the punch to the sheet metal blank through at least the first lubricant. The first electric current may flow from the sheet metal blank to the punch through at least the first lubricant. The first electric current may flow from the punch to the die through at least the second lubricant. The first electric current may flow from the die to the punch through at least the second lubricant. The first electric current may flow from the die to the sheet metal blank through at least the second lubricant. The first electric current may flow from the sheet metal blank to the die through at least the second lubricant. The second electric current may flow from the punch to the die through at least the first lubricant. The second electric current may flow from the die to the punch through at least the first lubricant. The second electric current may flow from the punch to the metal product through at least the first lubricant. The second electric current may flow from the metal product to the punch through at least the first lubricant.

A variety of lubricants and lubricant configurations are useful with the disclosed methods. For example, the first lubricant and the second lubricant may be the same lubricant or different lubricants. In some examples, the first lubricant comprises an ionic liquid. In some examples, the first lubricant may comprise or further comprise one or more of an aqueous lubricant, an oil-based lubricant, a wax-based lubricant, a petroleum-based lubricant, synthetic esters, a polyol ester, a polyol-based lubricant, a polyalphaolefin, polyethylene glycol, glamour wax, fluidized paraffin, synthetic paraffin, paraffin oil, mineral oil, white vaseline, palm oil, natural wax, polyethylene wax, hydrogenated castor wax, bees wax, polyisobutylene, polyethylene glycol dioleate, a fatty acid, stearic acid, oleic acid, tall oils, recinoleic acid, palmitic acid, myristic acid, lauric acid, isostearic acid, a nonionic surfactant, an amine, morpholine, diethyl amino ethanolamine, or water. Useful ionic liquids include, but are not limited to, those comprising an imidazolium cation, an ammonium cation, a pyrrolidinium cation, a phosphonium cation, a trihexyl(tetradecyl)phosphonium cation, a tetrafluoroborate anion, a hexafluorophosphate anion, a phosphate anion, a bis(trifluoromethylsulfonyl)amide anion, a bis(oxalate)borate anion, a perfluoroalkyulphosphate anion, a <NUM>-n-<NUM>-methylimidazolium, a <NUM>-n-<NUM>,<NUM>-methylimidazolium, a <NUM>-Allyl-<NUM>-methylimidazolium, [C<NUM>C<NUM>IM][PF<NUM>], or [C<NUM>C<NUM>IM][BF<NUM>]. The second lubricant may comprise one or more of an ionic liquid, such as those described above, an aqueous lubricant, an oil-based lubricant, a wax-based lubricant, a petroleum-based lubricant, or a conductive lubricant. The amount of lubricant applied to the sheet metal blank may be controlled. In some cases, applying the first lubricant comprises establishing a loading of the first lubricant on the punch side of the sheet metal blank of from <NUM>/m<NUM> to <NUM>/m<NUM>. In some cases, applying the second lubricant comprises establishing a loading of the second lubricant on the die side of the sheet metal blank of from <NUM>/m<NUM> to <NUM>/m<NUM>.

As noted above, the coefficient of friction between the punch and the sheet metal blank or the metal product and between the die and the sheet metal blank may be controlled. Example coefficient of friction may correspond to or be determined as a standard coefficient of friction. Example standard coefficients of friction for between the sheet metal blank and/or the punch may independently be from about <NUM> to about <NUM>, such as from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or from <NUM> to <NUM>. The friction coefficient may be controlled, in some cases, by application of current. The application of current may also modify properties of the lubricants. For example, the current may adjust a viscosity of the lubricant, in some cases. The first lubricant or the second lubricant may independently exhibit a viscosity of from about <NUM> mPas to about <NUM> mPas during the drawing, such as from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, from <NUM> mPas to <NUM> mPas, or from <NUM> mPas to <NUM> mPas.

The methods described herein may be useful with a variety of metals and a variety of stamping or drawing operations. In some cases, the sheet metal blank comprises an aluminum alloy, such as a 3xxx series aluminum alloy, an AA3003 alloy, an AA3004 alloy, an AA3104 alloy, or an AA3105 alloy. The punch or the die may comprise steel. The metal product may optionally comprise a metal cup, a redrawn metal cup, or a metal bottle preform.

Systems are also disclosed herein. A system according to the invention is configured to performing the method according to the invention. A system according to the invention for making a metal product comprises a lubrication source for applying a first lubricant on a punch side of a sheet metal blank; a controllable current source for applying different amounts of current; and a punch and a die for drawing the sheet metal blank into a metal product. The controllable current source is electrically coupled to one or more of the punch, the die, or a contact point for applying current through the first lubricant while the sheet metal blank is drawn by the punch and the die into the metal product. The controllable current source is electrically coupled to one or more of the punch, the die, or a contact point for applying current through the first lubricant while the metal product is being ejected from the punch. According to the invention, the controllable current source is configured to apply a first current through the first lubricant during drawing of the sheet metal blank and to apply a second current through the first lubricant during ejection of the metal product, so that a coefficient of friction between the sheet metal blank and the punch during drawing of the sheet metal blank is larger than a coefficient of friction between the metal product and the punch during ejection of the metal product.

The disclosed techniques employing control over friction can be useful in manufacturing aluminum beverage containers, as well as other aluminum products. In some aspects, systems and methods for forming an aluminum beverage container using ultrasonic vibrations are disclosed, such as with or without controlling friction as described above by application of electric current to or through a lubricant, but where the friction can be controlled by application of ultrasonic vibration to the metal product or the stamping or drawing equipment. It is noted that systems and methods using only vibrations to control friction do not pertain to the present invention that is defined by the appended claims.

Various examples utilize a die for receiving a container preform. The walls and base of the container preform may be engaged with one end of a ram, also referred to in some cases as a punch. The ram and a container preform or other metal product, such as a sheet metal blank, may be aligned with an opening in the die and the ram may drive the container preform through the die opening along a linear path. The die may be vibrated by an ultrasonic device, for example as the container preform is driven through the opening, reducing the friction between the walls of the container preform and the opening in the die. The die may be vibrated at different frequencies and/or in different directions to reduce friction and/or prevent metal buildup on the die.

According to various examples, a container manufacturing system is provided. The container manufacturing system may include a ram, a die, and an ultrasonic device. The ram may be cylindrical and include a ram body and a ram nose on the distal end of the ram body. The ram nose may engage with a base of a container preform. The die may have an opening concentrically aligned with the ram. The die opening may be sized and shaped for receiving the container preform in response to the ram nose engaging with the base of the container preform and driving the container preform through the die opening. The ultrasonic device may be coupled with the die and cause the die to vibrate while the ram drives the container preform through the die opening.

According to various examples, a method of forming an aluminum beverage container is provided. The method may include receiving a container preform on a ram. The container preform may include a base coupled with sidewalls. The base may be engaged with a distal end of the ram. The method may include vibrating a die using an ultrasonic device connected to the die. The die may include an opening concentrically aligned with the ram and may be sized and shaped for receiving the container preform. The method may further include driving the container preform through the die opening with the ram by moving the ram in a linear direction through the die opening.

According to various examples, a die for forming an aluminum beverage container is provided. The die includes a body defining an opening sized and shaped for receiving a container preform in response to the container preform being driven by a ram through the die opening. An ultrasonic device may be coupled with the die, vibrating the die while the container preform is being driven through the die opening by the ram.

Other objects and advantages will be apparent from the following detailed description of non-limiting examples.

Described herein are techniques for improving the reliability of metal forming operations, such as stamping, drawing, redrawing, or ironing processes. In some cases, the disclosed techniques employ lubricants that can have their lubricating properties changed in real time, allowing for better and more precise control over forming operations, which may, in turn, reduce or limit the rate at which forming failures occur. In some cases, the disclosed techniques employ ultrasonic vibrations, such as to change frictional forces at a die during forming operations.

As an example, during the forming of a metal product from a metal sheet, the friction between the forming equipment (e.g., a punch and die or a stamp and die) and the sheet metal or a metal preform is adjusted through use of a lubricant that has its properties dynamically controlled through application of an electric current and/or voltage. As another example not pertaining to the invention, the friction between the forming equipment and the sheet metal or a metal preform can be adjusted through application of ultrasonic vibrations to the forming equipment or the sheet metal or metal preform to dynamically control friction. It is desirable to have a relatively high amount of friction between the forming equipment and the sheet metal blank or preform during a drawing or stamping process and also to have a relatively low amount of friction between the formed sheet metal product and the drawing or stamping equipment after the drawing or stamping is complete and during ejection or removal of the drawn sheet metal product from the forming equipment.

<FIG> provide schematic cross-sectional illustrations showing a sheet metal blank <NUM> being drawn into a metal cup <NUM> using a punch <NUM> and die <NUM> according to conventional techniques. In some cases, metal cup <NUM> may be referred to as a preform. As shown in <FIG>, prior to drawing, sheet metal blank <NUM> is held in place by die <NUM> and a blankholder <NUM>. During forming, punch <NUM> is moved in a downward direction and into an opening in die <NUM>, forming the sheet metal blank <NUM> into metal cup <NUM>, as shown in <FIG>. In some cases, punch <NUM> may be mounted on a ram and may optionally be referred to as a ram. Following completion of forming of metal cup <NUM>, punch <NUM> may be moved upward and metal cup <NUM> ejected downward, such as by injecting compressed gas between metal cup <NUM> and punch <NUM>.

In some cases, however, the drawing or ejection processes may not operate as reliably as are desirable, which can result in interruption to a manufacturing process. For example, if the friction forces on the punch side surface of sheet metal blank <NUM> and the die side surface of sheet metal blank <NUM> are not correctly balanced, sheet metal blank <NUM> may be destroyed, damaged, or may be improperly drawn. As another example, if the friction force on the punch side surface of metal cup <NUM> is too high, metal cup <NUM> may not be properly ejected and damage to metal cup <NUM> may occur. If damage to sheet metal blank <NUM> or metal cup <NUM> occurs, this may result in interruption to the drawing operation and subsequent manufacturing processes, which may be normally taking place on a short time scale and in repeated succession (e.g., drawing <NUM> or more cups per minute). Additionally, time consuming operations involving disassembly of die <NUM> and removal of damaged sheet metal may be incurred, further slowing the restart of manufacturing. By controlling the friction between the forming equipment and the metal being formed, the forming operation can be optimized, reducing or minimizing damage to the formed metal product and associated interruptions to the forming process. In some examples, the formed metal cup <NUM> may be a beverage container or a beverage container preform.

In this description, reference is made to alloys identified by AA numbers and other related designations, such as "series" or "3xxx. " For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot," both published by The Aluminum Association.

As used herein, a plate generally has a thickness of greater than about <NUM>. For example, a plate may refer to an aluminum product having a thickness of greater than about <NUM>, greater than about <NUM>, greater than about <NUM>, greater than about <NUM>, greater than about <NUM>, greater than about <NUM>, greater than about <NUM>, greater than about <NUM>, or greater than about <NUM>.

As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about <NUM> to about <NUM>. For example, a shate may have a thickness of about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or about <NUM>.

As used herein, a sheet generally refers to an aluminum product having a thickness of less than about <NUM>. For example, a sheet may have a thickness of less than about <NUM>, less than about <NUM>, less than about <NUM>, less than about <NUM>, less than about <NUM>, or less than about <NUM> (e.g., about <NUM>).

All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of "<NUM> to <NUM>" should be considered to include any and all subranges between (and inclusive of) the minimum value of <NUM> and the maximum value of <NUM>; that is, all subranges beginning with a minimum value of <NUM> or more, e.g. <NUM> to <NUM>, and ending with a maximum value of <NUM> or less, e.g., <NUM> to <NUM>. Unless stated otherwise, the expression "up to" when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt.

As used herein, the meaning of "a," "an," and "the" includes singular and plural references unless the context clearly dictates otherwise.

Described herein are methods of treating metals and metal alloys, including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, among others, and the resultant metal and metal alloy products. In some examples, the metals for use in the methods described herein include aluminum alloys, for example, 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys. In some examples, the materials for use in the methods described herein include non-ferrous materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal or combination of materials. Monolithic as well as non-monolithic, such as roll-bonded materials, cladded alloys, clad layers, or various other materials are also useful with the methods described herein. In some examples, aluminum alloys containing iron are useful with the methods described herein.

By way of non-limiting example, exemplary 1xxx series aluminum alloys for use in the methods described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein can include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149,<NUM>, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

The metals described herein can be cast using any suitable casting method. As a few non-limiting examples, the casting process can include direct chill casting (including direct chill co-casting), semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method. Cast metals may be in the form of cast ingots, cast slabs, cast billets, or other cast products. Cast products can be processed by any suitable means. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and an optional pre-aging step. In some examples, cast metal products can be processed to form rolled metal products, such as metal sheets, metal shates, or metal plates. Metal sheets, for example, may be provided as a rolled coil of sheet metal, and may be sectioned or punched to form a metal blank. Rolled metal products may be subjected to additional forming processes (e.g., stamping, drawing, ironing, or the like) to shape the material into a particular orientation or profile for a target application.

The disclosed methods include processes of forming a metal or metal alloy into a formed metal or metal alloy product. Specific reference to forming processes involving sheet metal are described below, but other metal products, such as metal shates or metal plates, may also be subjected to forming processes.

During forming of metal sheets, friction between a metal sheet and the forming equipment, such as stamping equipment or drawing equipment, can impact how the metal comprising the metal sheet will flow. As an example, if the friction is not properly distributed, the metal may not form as desired, resulting in excess or insufficient flow of material in various directions. For example, if the friction is too large for a particular forming operation, the metal can fracture or tear due to the forces that are generated during forming, resulting in an opening, crack, or separation within the metal product. If the friction is too small for a particular forming operation, the metal could be partially or completely ejected from the forming equipment in an undesirable way.

To control friction, lubricants are placed between the metal sheet and the forming equipment. Lubricants may also be used as coolants during some forming processes, as the forming process itself can generate heat. In some cases, lubrication is used over an entire surface of a metal sheet during a forming process. In other cases, only portions of a metal sheet receive lubrication. Different lubricants may be used to establish different friction coefficients between a metal sheet and the forming equipment, but generally the friction coefficient under conventional operations does not change unless there is a change in the amount or type of lubricant used. For some operations, however, it is desirable to change the friction coefficient in real time without having to change the amount or type of lubricant. The systems and methods according to the invention employ a lubricant that changes properties by application of an electric voltage and/or current, such as to allow for control over the friction coefficient between two components.

The friction coefficient is controlled between forming equipment and a metal product during and after a forming operation. Use of an electrically controllable lubricant allows the friction coefficient between a metal product and forming equipment to change, such as to allow for one friction coefficient to be used during forming and another friction coefficient to be used during removal of the metal product from the forming equipment.

<FIG> provides a schematic illustration of an example forming system <NUM> according to an embodiment of the invention allowing for control over friction coefficients at various processing times. Forming system <NUM> comprises a punch <NUM>, a die <NUM>, a first lubrication source <NUM>, a second lubrication source <NUM>, a blankholder <NUM>, and a current source <NUM>. First lubrication source <NUM> and second lubrication source <NUM> may comprise any suitable equipment for applying a first lubricant <NUM> and a second lubricant <NUM>, respectively, to metal sheet <NUM>. For purposes of illustration, first lubrication source <NUM> and second lubrication source <NUM> are depicted as comprising spray nozzles for applying first lubricant <NUM> to a punch side surface of metal sheet <NUM> and second lubricant <NUM> to a die side surface of metal sheet <NUM>.

Current source <NUM> is electrically coupled to one or more of punch <NUM>, die <NUM>, or another contact point for applying electric current to or through the first lubricant <NUM> and/or the second lubricant <NUM> that is applied to surfaces of metal sheet <NUM> at various stages of a forming operation in order to modify the lubricant properties and adjust friction. Current source <NUM> may provide a voltage between punch <NUM> and die <NUM> to allow for a current to pass through first lubricant <NUM>, metal sheet <NUM>, and second lubricant <NUM>. The direction of current flow may be alterable, and the current may flow in a forward direction or a reverse direction, depending on the voltage applied. Forward and reverse currents may provide advantages for some configurations or for adjusting a friction coefficient. Similarly, the magnitude of the applied current may also be used for adjusting the friction coefficients. Optionally, the current may correspond to an alternating current or a direct current, applied by application of an AC voltage or a DC voltage between punch <NUM> and die <NUM>. Although current source <NUM> is shown as in electrical communication directly with punch <NUM> and die <NUM>, the electrical communication of current source <NUM> with punch <NUM> and die <NUM> may be indirect, such as where one or more intervening circuits or conductive components are present between current source <NUM> and punch <NUM> or die <NUM>.

The current applied is suitable for achieving a desired friction coefficient or desired property of a lubricant. As examples, currents of from <NUM> mA to <NUM> A may be applied. In some cases, a current of <NUM> A (i.e., no current) may be used during certain forming operations. The friction coefficients that can be achieved may depend on the materials and compositions of the metal sheet <NUM>, punch <NUM>, die <NUM>, first lubricant <NUM>, and second lubricant <NUM>, the magnitude and direction of the applied current and/or the voltage used to generate the current. As examples, friction coefficients ranging from <NUM> to <NUM> may be achieved. In some cases, the friction coefficient for a particular system may be referred to as a standard friction coefficient, which may be determined using a standard friction test according to an ASTM standard, such as an ASTM G115 standard, for example ASTM G115-<NUM>(<NUM>), Standard Guide for Measuring and Reporting Friction Coefficients, ASTM International, West Conshohocken, PA, <NUM>.

As noted above, the properties of the first lubricant <NUM> and/or the second lubricant <NUM> are changed by the application of electric current to or through the lubricant(s). The effective property to be changed for the applications described herein may relate to modification of the friction coefficient between different surfaces lubricated by the lubricant, but other properties may relate to or be affected by or effect a change in the friction. For example, a viscosity of the first lubricant <NUM> and/or the second lubricant <NUM> may be changed by the application of electric current to or through the lubricant(s). In some cases, the viscosity of the first and/or second lubricant may optionally and independently vary from <NUM> mPas to <NUM> mPas. Optionally, application of an electric current to or through the lubricant(s) may increase or decrease the viscosity of the lubricant(s). Optionally, changing the viscosity may change friction. These property changes may occur in a controllable and reversible fashion, such that applying no current, followed by applying a current, followed by applying no current again may reversibly change the property to its original state. Without being bound by theory, the change in properties of the lubricant(s) may optionally arise through modifying the orientation and/or arrangement of the molecules or ions within the lubricant(s). In the case of lubricants comprising ionic liquids, for example, the ions of the ionic liquid (cations and anions) may be physically separated in space and/or oriented in particular directions by the application of electric current. In some cases, the orientation or arrangement of ions may be directed through application of a voltage.

Depending on the configuration and desired friction coefficients between metal sheet <NUM> and components of forming system <NUM>, first lubricant <NUM> and second lubricant <NUM> may be the same or different. In some examples, punch <NUM> and die <NUM> comprise steel, while metal sheet <NUM> comprises an aluminum alloy. Optionally, first lubricant <NUM> or second lubricant <NUM> may comprise an ionic liquid, such as a salt that is molten at temperatures of less than about <NUM>, such as from <NUM> to <NUM>. Example ionic liquids may comprise an imidazolium cation, an ammonium cation, a pyrrolidinium cation, a phosphonium cation, a trihexyl(tetradecyl)phosphonium cation, a tetrafluoroborate anion, a hexafluorophosphate anion, a phosphate anion, a bis(trifluoromethylsulfonyl)amide anion, a bis(oxalate)borate anion, a perfluoroalkyulphosphate anion, a <NUM>-n-<NUM>-methylimidazolium, a <NUM>-n-<NUM>,<NUM>-methylimidazolium, or a <NUM>-Allyl-<NUM>-methylimidazolium, such as [C<NUM>C<NUM>IM][PF<NUM>] and [C<NUM>C<NUM>IM][BF<NUM>]. In some cases, first lubricant <NUM> or second lubricant <NUM> may comprise an aqueous lubricant, an oil-based lubricant, a wax-based lubricant, a petroleum-based lubricant, or a conductive lubricant. In some cases, a lubricant blend may be used, such as a lubricant comprising one or more of an ionic liquid, an aqueous lubricant, an oil-based lubricant, a wax-based lubricant, a petroleum-based lubricant, a conductive lubricant, synthetic esters, a polyol ester, a polyol-based lubricant, a polyalphaolefin, polyethylene glycol, glamour wax, fluidized paraffin, synthetic paraffin, paraffin oil, mineral oil, white vaseline, palm oil, natural wax, polyethylene wax, hydrogenated castor wax, bees wax, polyisobutylene, polyethylene glycol dioleate, a fatty acid, stearic acid, oleic acid, tall oils, recinoleic acid, palmitic acid, myristic acid, lauric acid, isostearic acid, a nonionic surfactant, an amine, morpholine, diethyl amino ethanolamine, or water.

First lubrication source <NUM> and second lubrication source <NUM> may be used to establish any suitable loading of lubricants on the surfaces of metal sheet <NUM>. For example, lubricant loadings may optionally range from <NUM>/m<NUM> to <NUM>/m<NUM>. First lubrication source <NUM> and second lubrication source <NUM> are depicted in <FIG> as positioned to apply first lubricant <NUM> and second lubricant <NUM> to metal sheet <NUM> prior to the metal sheet being inserted between die <NUM> and blankholder <NUM> / punch <NUM>. Other arrangements of first lubrication source <NUM> and second lubrication source <NUM> may alternatively be used. Optionally, first lubrication source <NUM> may apply first lubricant <NUM> to punch <NUM>. Optionally, second lubrication source <NUM> may apply second lubricant <NUM> to die <NUM>.

To control the friction between metal sheet <NUM> and punch <NUM>, first lubricant <NUM> is a controllable lubricant, such as comprising an ionic liquid, and a current is applied to or through the first lubricant <NUM>. Similarly, to control the friction between metal sheet <NUM> and die <NUM>, second lubricant <NUM> may be a controllable lubricant, such as comprising an ionic liquid, and a current may be applied to or through the second lubricant <NUM>. <FIG> depicts an expanded view of a section of forming system <NUM> at the beginning of or prior to the drawing process, and shows metal sheet <NUM>, coated with first lubricant <NUM> and second lubricant <NUM> on opposite sides, punch <NUM>, die <NUM> and current source <NUM>. In the illustrated configuration, current may flow from punch <NUM>, through first lubricant <NUM>, metal sheet <NUM>, and second lubricant <NUM> to die <NUM>, or vice versa.

<FIG> depicts an expanded view of the section of forming system <NUM> shown in <FIG> during the drawing process, with punch <NUM> depicted as moving in a downward direction relative to die <NUM>. The friction coefficient between metal sheet <NUM> and punch <NUM> is tei be greater than the friction coefficient between metal sheet <NUM> and die <NUM> during drawing of metal sheet <NUM>, so the compositions of first lubricant <NUM> and second lubricant <NUM> may be different, and the magnitude and direction of the applied current is selected to achieved this. In one example, first lubricant <NUM> may comprise an ionic liquid having properties that can vary as a function of the applied voltage and/or current, while second lubricant <NUM> may comprise an oil-based lubricant having properties that do not vary as a function of the applied voltage and/or current. In other cases, it may be desirable for different friction coefficients to be used, so the applied voltage and/or current may be different and the compositions of first lubricant <NUM> and second lubricant <NUM> may be different.

As the drawing process completes, as shown in <FIG>, motion of punch <NUM> in the downward direction relative to die <NUM> stops. At this point, the desired friction coefficients may change, so the application of current or voltage by current source <NUM> may change. For example, it may be desirable to reduce the friction coefficient between metal sheet <NUM> and punch <NUM> to as low a value as possible to allow for easy removal or separation of punch <NUM> from metal sheet <NUM>, so the applied current and/or voltage is altered from that used during the forming process as depicted in <FIG>.

<FIG> depicts the ejection of metal sheet <NUM>, now drawn into a metal cup, from forming system <NUM>, with metal sheet <NUM> moving in a downward direction relative to die <NUM> and punch <NUM> moving in an upward direction relative to die <NUM>. For purposes of illustration, first lubricant <NUM> and second lubricant <NUM> are shown as being retained on metal sheet <NUM>, but some amount of first lubricant <NUM> may be retained on punch <NUM> and some amount of second lubricant <NUM> may be retained on die <NUM>.

<FIG> depicts a cross-sectional side view of a portion of a container manufacturing system <NUM>, which is not in accordance with the claimed invention. The container manufacturing system <NUM> may include a container preform <NUM>, a ram <NUM>, a die <NUM>, and one or more ultrasonic devices <NUM>.

The container preform <NUM> may be a piece of metal that has been formed into a shape (e.g., a can, a cup, a bottle preform, or the like). In various examples, the container preform <NUM> may be driven through a die, such as die <NUM>, to form a shallow cup. The container preform <NUM> may include a base <NUM> and sidewalls <NUM>. The container preform <NUM> may be aligned with and/or engaged with the ram <NUM> via the sidewalls <NUM> and/or the base <NUM>. In some examples, the container preform <NUM> may be aligned with the ram <NUM> and the die <NUM> via a cup locator.

The container preform <NUM> may have an inner diameter <NUM>, a starting wall thickness <NUM>, and a reduced wall thickness <NUM>. In various examples, the container preform <NUM> may have an inner diameter <NUM> of from <NUM> to <NUM>, a starting wall thickness <NUM> of from <NUM> to <NUM>, and/or a reduced wall thickness <NUM> of from <NUM> to <NUM>.

In various examples, the ram <NUM> may have a cylindrical shape for receiving and engaging with the container preform <NUM>. The ram <NUM> may engage with and drive the container preform <NUM> through an opening <NUM> in the die <NUM>. The ram <NUM> may engage with the base <NUM> of the container preform <NUM> and/or the sidewalls <NUM> of the container preform <NUM>. For example, the end of the ram <NUM> may be engaged with the base <NUM> and the sides of the ram <NUM> may be engaged with the sidewalls <NUM>. In some examples, the ram <NUM> may be driven through and withdrawn from the die <NUM> in a repeating pattern. For example, the ram <NUM> may engage with and drive a first container preform <NUM> through the die <NUM> in a first direction, disengage from the first container preform <NUM>, retract through the die <NUM> in a second direction, and engage with and drive a second container preform <NUM> through the die <NUM> in the first direction, starting the cycle anew. In various examples, the ram <NUM> may be linearly driven through the die <NUM> using a flywheel, compressed fluid, air, a swing lever or other suitable mechanism. The ram <NUM> may be or include tool steel or carbide. In various examples, the ram <NUM> may correspond to or comprise components of a container preform body maker.

In some examples, the ram <NUM> may include a ram body <NUM>, a punch sleeve <NUM>, and/or a punch nose <NUM>. A first end of the ram body <NUM> may be attached to a driving device for moving the ram <NUM> along a linear path and a second opposing end of the ram body <NUM> may be attached to the punch sleeve <NUM> and/or the punch nose <NUM>. The punch sleeve <NUM> may engage with the sidewalls <NUM> of the container preform <NUM> and hold the container preform <NUM> against the die <NUM> to aid in the reduction of the sidewall thickness (e.g., from a starting wall thickness <NUM> to a reduced wall thickness <NUM>). The punch sleeve <NUM> may have a constant diameter (e.g., similar to the inner diameter <NUM> of the container preform <NUM>) or may have a variable diameter. In some examples, the punch nose <NUM> engages with the base <NUM> of the container preform <NUM> and aids in the reduction of the diameter of the container preform <NUM>. Each side of the punch nose <NUM> may terminate at a contact point <NUM>. The two contact points <NUM> may be set apart by a distance less than the inner diameter <NUM>. However, the two contact points <NUM> may be set apart by a distance equal to the inner diameter <NUM>.

One or more dies <NUM> may be used in combination with the ram <NUM> to reduce the wall thickness (e.g., from a starting wall thickness <NUM> to a reduced wall thickness <NUM>) of the container preform <NUM>. In some examples, the one or more dies <NUM> are part of a die assembly <NUM>, discussed herein with respect to <FIG>, and/or are part of a tool pack <NUM>, discussed herein with respect to <FIG>.

In various examples, the die <NUM> may include an opening <NUM> sized and shaped for receiving the container preform <NUM> and/or the ram <NUM>. For example, the opening <NUM> may be an elliptical or circular shaped opening. In various examples, the die <NUM> has an elliptical opening <NUM> with a diameter less than the combination of the inner diameter <NUM> of the container preform <NUM> and twice the starting wall thickness <NUM>. In some examples, the elliptical opening <NUM> may have a diameter of from <NUM> to <NUM> (such as, but not limited to, from <NUM> to <NUM>). The opening <NUM> may compress the sidewalls <NUM> of the container preform <NUM> from the starting wall thickness <NUM> to the reduced wall thickness <NUM>. Compressing the sidewalls <NUM> may increase the length of the sidewalls.

As an illustrative non-limiting example, the container preform <NUM> has an inner diameter <NUM> of from <NUM> to <NUM> and a starting wall thickness <NUM> of from <NUM> to <NUM> for a total thickness of from <NUM> to <NUM> (i.e., <NUM> + <NUM> × <NUM> and <NUM> + <NUM> × <NUM>). The inner diameter <NUM> contacts the ram <NUM> and remains constant while the starting wall thickness <NUM> is compressed to the reduced wall thickness <NUM>. The opening <NUM> is a circular opening with a diameter of from <NUM> to <NUM> that receives the container preform <NUM> on the ram <NUM>. The ram <NUM> drives the container preform <NUM> through the opening <NUM>, reducing the overall diameter of the container preform to equal the diameter of the opening (e.g., from <NUM> to <NUM>). The reduced overall diameter of the container preform <NUM> results in the container preform having a reduced wall thickness <NUM>.

In some examples, multiple dies <NUM> may be used to progressively decrease the thickness of the sidewalls <NUM> of the container preform <NUM> (e.g., the reduced wall thickness <NUM> of a first die may be the starting wall thickness <NUM> of a second die). For example, three dies <NUM> may be positioned in series. In such a scenario, each respective die may have an opening that is progressively smaller than the opening of the immediately preceding die. As the container preform <NUM> is driven through each successive die <NUM>, the sidewalls <NUM> are progressively compressed. This compression may cause the sidewalls <NUM> to be made progressively thinner. This may additionally or alternatively cause the sidewalls <NUM> to become progressively longer. In some examples, only a portion of the container preform <NUM> may contact multiple dies, for example, due to the positioning of the dies <NUM> and/or the ram <NUM> having a diameter that progressively narrows from the distal end to the proximal end. In further examples, as the ram <NUM> drives the container preform <NUM> through the opening <NUM> of the die <NUM>, the diameter of the ram <NUM> engaged with the base <NUM> of the container preform <NUM> may cause the base <NUM> to contact all of the dies <NUM> and the narrower diameter of the ram <NUM> engaged with the sidewalls <NUM> of the container preform <NUM> may contact some and/or none of the dies <NUM>.

One or more ultrasonic devices <NUM> may be coupled with the one or more dies <NUM> to vibrate the dies <NUM>. One ultrasonic device <NUM> may be coupled with a single die <NUM> or may be coupled with multiple dies <NUM>. The ultrasonic device <NUM> may be coupled with the dies <NUM> and positioned to vibrate the dies <NUM> in a radial direction (e.g., in direction <NUM>) and/or in an axial direction (e.g., in direction <NUM>). The ultrasonic device <NUM> may be a device that produces mechanical waves or oscillations at a frequency. For example, the ultrasonic device <NUM> may generate a frequency in a range of from <NUM> to <NUM>, such as from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or anywhere in between (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc). The ultrasonic device <NUM> may include an electronic oscillator and a transducer. The electronic oscillator may produce an alternating current oscillating at a frequency. The transducer may be attached to the die <NUM> and convert the oscillating current to a mechanical vibration to vibrate the die <NUM>. The transducer may correspond to or comprise a piezoelectric transducer or a magnetostrictive transducer or other suitable transducer. In some examples, the ultrasonic device <NUM> may include a sonotrode positioned between the transducer and the die <NUM> to cause the die <NUM> to vibrate.

In some examples, the ultrasonic device <NUM> causes the die <NUM> to vibrate and reduce the friction between the container preform <NUM> and the die <NUM>. Reducing the amount of friction between the die <NUM> and the container preform <NUM> may allow for a greater reduction in wall thickness of the container preform <NUM> and/or use of a container preform <NUM> with a thinner starting wall thickness <NUM>. Additionally or alternatively, reducing the amount of friction between the die <NUM> and the container preform <NUM> may reduce the number of die assemblies <NUM> needed in the container manufacturing system <NUM>. Reducing the amount of friction may allow different metal to be used in the container preform <NUM> and/or allow for less and/or alternative lubrication to be used in the manufacturing process.

In various examples, the ultrasonic device <NUM> may vibrate the die <NUM> to reduce buildup of metal on the die <NUM>. The buildup of metal may be the result of the container preform <NUM> contacting the die <NUM>. For example, each time a container preform <NUM> is driven through the die <NUM>, a small amount of metal may be deposited on the die <NUM>. Reduction of metal on the die <NUM> may reduce the amount of friction between the die <NUM> and the container preform <NUM>. The reduction of metal on the die <NUM> may additionally or alternatively increase the functional life of the die <NUM>.

In further examples, the ultrasonic device <NUM> may vibrate the die <NUM> to reduce internal stresses in the container preform <NUM>. The reduction of internal stresses in the container preform <NUM> may result in fewer tear off and/or less work hardening of the container preform.

<FIG> is an illustration of an exploded view of an example die assembly <NUM> for use with the container manufacturing system <NUM> of <FIG>, which is not in accordance with the claimed invention. The die assembly <NUM> may include one or more spacers. As shown, die assembly <NUM> includes two spacers 802A and 802B (also collectively or individually referred to herein as spacers <NUM>), a die <NUM>, and multiple ultrasonic devices <NUM>, however, the die assembly <NUM> may include an additional and/or an alternative number of components.

The die <NUM>, as pictured, is a circular plate with a circular opening <NUM> for receiving a container preform <NUM> engaged with a ram. As discussed in reference to <FIG>, the opening <NUM> has a diameter smaller than the received container preform <NUM> to reduce the wall thickness of the container preform. The die <NUM> may include metal and/or other material strong enough to retain its shape while resisting the force of the punch driving the container preform <NUM> through the opening <NUM>. In various examples, multiple dies <NUM> may be used, each with a differently sized diameter. In some examples, the die <NUM> may correspond to or comprise a redraw die, an ironing die, or a pilot die.

The die <NUM> may be coupled with, and held in place by, one or more spacers <NUM> during the forming process. The spacers <NUM> may be positioned on opposing sides of one or more dies <NUM>. The spacers <NUM> may additionally or alternatively be positioned between dies <NUM> allowing the container preform <NUM> to be in contact with only one die <NUM> at a time. The spacers <NUM> may provide an area for lubrication to be added to the container preform <NUM> and/or the die <NUM> during the forming process.

As illustrated in <FIG>, two spacers 802A and 802B are used to hold the die <NUM>, one placed on either side of the die. The spacers <NUM> may include a recessed area <NUM> sized and shaped surrounding the outer diameter of the die <NUM>. For example, the recessed area may be sized and shaped to receive the die <NUM> and hold the die in place. The spacers <NUM> may include an aperture <NUM>. The aperture <NUM> may have the same or similar shape as the opening <NUM> in the die <NUM>. The aperture <NUM> may be larger than the opening <NUM> of the die <NUM>. The spacers <NUM> may include mounting points for ultrasonic devices 740A, 740B, and 740C. The ultrasonic devices 740A, 740B, and 740C may be mounted for vibrating the die <NUM> along one or more directions. For example, ultrasonic devices 740B may be mounted for vibrating of the die <NUM> along direction <NUM>. Additionally or alternatively, ultrasonic devices 740A and/or 740C may be positioned for vibrating the die <NUM> along direction <NUM>. In some examples, the spacers <NUM> may include additional or alternative mounting points for the ultrasonic devices 740A, 740B, and 740C and/or channels for lubrication or cable routing.

In examples where multiple spacers <NUM> are used, less than all spacers may be coupled with ultrasonic devices. For example, if two spacers <NUM> are used, a first spacer may be devoid of ultrasonic devices while a second spacer may be coupled with an ultrasonic device, for example, 740A, 740B, and/or 740C.

The ultrasonic devices 740A, 740B, and 740C may be coupled with the spacers and vibrate the die <NUM> at an ultrasonic frequency. The die <NUM> vibrating at an ultrasonic frequency may reduce friction between the die <NUM> and the container preform <NUM> when the container preform <NUM> is being driven through the die <NUM>. Additionally or alternatively, the die <NUM> vibrating at an ultrasonic frequency may reduce metal buildup that may occur on the die <NUM>.

Shown in <FIG> are various mounting options for the ultrasonic devices 740A, 740B, and 740C, however, the ultrasonic devices may be mounted in any suitable configuration. In the example of <FIG>, two pairs of opposing ultrasonic devices 740A, 740C are on spacer 802A to point radially inward toward the aperture <NUM> and two pairs of ultrasonic devices 740B are mounted on opposing spacers 802A, 802B.

Mounting ultrasonic devices 740A, 740B, and 740C in pairs may allow resulting vibrations to be balanced. For example, balancing the vibrations may at least partially counteract or prevent substantial amounts of vibrations from traveling outside of the die <NUM>, such as into the spacers <NUM> or beyond.

<FIG> is a flowchart illustrating an example of a process <NUM> for using a container manufacturing system to form an aluminum container, which is not in accordance with the claimed invention, The process <NUM> at <NUM> may include receiving a container preform, such as container preform <NUM>, into a container manufacturing system, such as container manufacturing system <NUM>. The container preform <NUM> may have a base and walls for engaging with a ram, such as ram <NUM>, as explained herein. In some examples, the container preform <NUM> is received from a cutting machine. In various examples, the container preform <NUM> is positioned in the container manufacturing system <NUM> using a cup locator.

The process <NUM> at <NUM> includes vibrating a die assembly, such as the die assembly <NUM> described herein. The die assembly <NUM> may be vibrated using an ultrasonic device, such as ultrasonic device <NUM>. The ultrasonic device <NUM> may vibrate some or all of the die assembly <NUM>. For example, the ultrasonic device <NUM> may vibrate the die <NUM> and/or the one or more spacers <NUM>. The ultrasonic device <NUM> may be connected to the die assembly <NUM> to vibrate the die assembly along one or more directions. For example, the ultrasonic device <NUM> may be placed at one or more various points in the die assembly <NUM> to vibrate the die assembly <NUM> in a radial direction. Additionally or alternatively, the ultrasonic device <NUM> may vibrate the die assembly <NUM> in an axial direction. In some examples, the ultrasonic device <NUM> may vibrate the die assembly <NUM> in multiple directions. Multiple directions of vibrations may be imparted simultaneously or sequentially. As an illustrative example of sequentially imparting multiple directions of vibrations, the ultrasonic device <NUM> may vibrate the die assembly <NUM> axially when the container preform <NUM> is driven through the die <NUM> and radially when the ram <NUM> is retracting through the die assembly.

In various examples, vibrating the die assembly <NUM> may be implemented during or in between other listed actions (e.g., <NUM>-<NUM>). For example, the die assembly <NUM> may be vibrated before, during, and/or after the process <NUM> at <NUM>, where the container preform <NUM> is driven through the opening <NUM> by the ram <NUM>. Vibrating the die assembly <NUM> may occur during any and/or all of the actions <NUM>-<NUM>. Vibrating the die assembly <NUM> between and/or before actions may allow the die assembly <NUM> to shake off a build-up of metal shavings and/or lubrication. In some examples, the die assembly <NUM> may be vibrated at multiple frequencies depending on the action taking place and/or whether an action is taking place at all.

The process <NUM> at <NUM> includes engaging the container preform <NUM> with the ram <NUM>. The ram <NUM> engages the container preform <NUM> by moving along a linear path until an end of the ram <NUM> is engaged with the base and/or walls of the container preform <NUM>. In some examples, the ram <NUM> may be moved along the linear path via a flywheel and engage the container preform <NUM>. In some examples, the ram <NUM> engages the container preform <NUM> via a punch nose, such as the punch nose <NUM>.

The process <NUM> at <NUM> includes driving the container preform <NUM> through the vibrating die assembly <NUM>. For example, the container preform <NUM> may be driven through the opening <NUM> in the die <NUM> via the ram <NUM>. In some examples, the opening <NUM> may have a size and shape that is smaller than the size and shape of the container preform <NUM>. For example, the opening <NUM> may have a diameter that is smaller than the inner diameter <NUM> of the container preform <NUM>. The opening <NUM> having a smaller size and shape may cause the sidewalls <NUM> of the container preform <NUM> to compress, reducing the thickness of the sidewalls when the container preform <NUM> is driven through opening <NUM> of the die <NUM>. In various examples, vibrating the die assembly <NUM> at <NUM> may reduce the friction between the container preform <NUM> and the die <NUM> when the container preform <NUM> is being driven through the opening <NUM>. For example, vibrating the die assembly <NUM> reduces the amount of friction that would otherwise occur between the container preform <NUM> and the die <NUM> when the thickness of the sidewalls <NUM> of the container preform <NUM> is reduced.

The process <NUM> at <NUM> includes retracting the ram <NUM> through the die assembly <NUM>. In some examples, vibrating the die assembly <NUM> (i.e., process <NUM> at <NUM>) may occur simultaneously with the ram <NUM> being retracted through the die assembly <NUM> (i.e., process <NUM> at <NUM>). The ultrasonic device <NUM> may vibrate the die assembly <NUM> in the same direction and/or at the same frequency as when the container preform <NUM> is being driven through the die assembly <NUM>. However, the ultrasonic device <NUM> may vibrate the die assembly <NUM> in a different direction and/or at a different frequency than when the container preform <NUM> is being driven through the die assembly <NUM>. Additionally or alternatively, the die assembly <NUM> may not be vibrated at all as the ram <NUM> is retracted, or the die assembly <NUM> may be vibrated while the ram <NUM> is retracted at <NUM> and not while the container preform is being driven at <NUM>. After retraction through the die assembly <NUM>, the container manufacturing system <NUM> may receive an additional container preform <NUM> to be driven through the die assembly <NUM>.

<FIG> is an example tool pack <NUM> of the container manufacturing system of <FIG> which is not in accordance with the claimed invention. The tool pack <NUM> includes a non-vibrating die assembly 800A and a vibrating die assembly 800B. The vibrating die assembly 800B is connected to and vibrated by the ultrasonic device <NUM>.

The non-vibrating die assembly 800A may include one or more spacers 802A and one or more non-vibrating dies 730A. The spacers 802A may be positioned such that the non-vibrating die 730A and the vibrating die 730B are separated by at least one spacer 802A. For example, the non-vibrating die 730A may be separated from the vibrating die 730B by spacer 802A. The non-vibrating die assembly 800A may receive a container preform <NUM> driven by a ram <NUM>. The non-vibrating die 730A may be or include a non-vibrating die (e.g., a redraw die or a first ironing die).

The vibrating die assembly 800B may include one or more spacers 802B and one or more dies 730B. The vibrating die assembly 800B may be connected with an ultrasonic device <NUM> that vibrates one or more components of the die assembly 800B. For example, the ultrasonic device <NUM> may be connected with the dies 730B to vibrate the dies. The ultrasonic device <NUM> may be positioned to vibrate the dies 730B radially. Additionally or alternatively, the ultrasonic device <NUM> may be positioned to vibrate the dies 730B axially. The ultrasonic device <NUM> may vibrate the dies 730B before, during, and/or after the container preform <NUM> is driven through the non-vibrating die assembly 800A. One ultrasonic device <NUM> may be individually connected each of the dies 730B and/or spacer 802B. However, one ultrasonic device <NUM> may be connected to multiple dies 730B and/or spacers 802B. The ultrasonic device <NUM> may also correspond to multiple ultrasonic devices <NUM>.

The tool pack <NUM> may include different combinations and/or patterns of non-vibrating die assemblies 800A and vibrating die assemblies 800B. In some examples, the tool pack <NUM> includes multiple sets of non-vibrating die assemblies 800A and one vibrating die assembly 800B. For example, two non-vibrating die assemblies 800A may be positioned before one vibrating die assembly 800B, such that, the container preform <NUM> is driven through the non-vibrating die assemblies 800A before being driven through the vibrating die assembly 800B. However, non-vibrating die assembly 800A may be positioned after the vibrating die assembly 800B and/or on either side of the vibrating die assembly 800B.

The tool pack <NUM> may include multiple sets of vibrating die assemblies 800B. The multiple sets of vibrating die assemblies 800B may be positioned before a non-vibrating die assembly 800A, after a non-vibrating die assembly 800A, and/or on either side of a non-vibrating die assembly 800A. In some examples, the tool pack <NUM> may include only one vibrating die assembly 800B without any accompanying non-vibrating die assembly 800A.

The metal products and associated methods described herein can be used in automotive applications and other transportation applications, including aircraft and railway applications, or any other desired application. For example, the disclosed metal products can be used to prepare automotive structural parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The metal products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.

The metal products and associated methods described herein can also be used in electronics applications. For example, the metal products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the metal products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis, and other portable electronics.

Claim 1:
A method of making a metal product, comprising the following steps:
applying a first lubricant (<NUM>) on a punch side of a sheet metal blank (<NUM>);
applying a second lubricant (<NUM>) on a die side of the sheet metal blank (<NUM>);
drawing the sheet metal blank (<NUM>) using a punch (<NUM>) and a die (<NUM>) to form the sheet metal blank (<NUM>) into a metal product;
ejecting the metal product from the die (<NUM>);
characterized in that the step of drawing the sheet metal blank (<NUM>) is performed while controlling one or both of a first coefficient of friction between the punch side of the sheet metal blank (<NUM>) and the punch (<NUM>) and a second coefficient of friction between the die side of the sheet metal blank (<NUM>) and the die (<NUM>) such that the first coefficient of friction is greater than the second coefficient of friction; and
the step of ejecting the metal product from the die (<NUM>) is performed while controlling a third coefficient of friction between the metal product and the punch (<NUM>) to be less than the first coefficient of friction;
and wherein controlling the first coefficient of friction comprises applying a first electric current through the first lubricant (<NUM>) or applying the first electric current through the second lubricant (<NUM>), and wherein controlling the third coefficient of friction comprises applying a second electric current through the first lubricant (<NUM>).