Patent ID: 8434342

Claim:
A method of forming a cup-shaped circular can shell from a flat metal sheet with tooling installed within a single action mechanical press, the shell including a center panel connected by an annular panel wall to an annular countersink having a generally U-shaped cross-sectional configuration and with the countersink connected to an inner wall portion of an annular crown by an inclined annular chuckwall, the method comprising the steps of blanking a disk from the sheet between a blank and draw die and an opposing cut edge die, gripping an annular portion of the disk between an annular die core ring within the cut edge die and an opposing annular outer pressure sleeve supported within the blank and draw die by a die center piston, engaging an annular inner portion of the disk with an annular nose portion of an annular inner pressure sleeve supported within the outer pressure sleeve while the nose portion is projecting axially from a die center punch retracted within the inner pressure sleeve, pressurizing the inner pressure sleeve with air springs produced by air spring passages extending from an air reservoir chamber within the die center piston, initiating the drawing of a cup within the disk with the projecting nose portion of the inner pressure sleeve while the nose portion is projecting from the die center punch, thereafter engaging a center portion of the disk with the die center punch within the inner pressure sleeve, forming the chuckwall of the shell by continuing the drawing of the cup with the die center punch until the inner pressure sleeve clamps an inclined annular portion of the disk against the die core ring, pressing the center portion of the disk with the die center punch against a panel punch within the die core ring to form the center panel of the shell and to complete forming of the cup, and reversing the direction of the panel punch and the die center punch while continuing to clamp the chuckwall between the inner pressure sleeve and the die core ring to form the panel wall and countersink of the shell with a contoured surface on a peripheral portion of the panel punch.