An experimental and numerical study of the wall ironing process of polymer coated sheet metal

摘要

In the traditional manufacturing process for metal food and beverage containers, a food contact-safe lacquer is sprayed onto the can before filing. This time consuming and therefore expensive process can be eliminated using a polymer coated sheet metal provided that the polymer will survey the manufacturing operations. The most critical stage in can making is the ironing process because of the large deformations that occur. This paper presents experimental and numerical results regarding the ironing process of polymer coated aluminum and polymer coated steel. A plane strain strip ironing device has been constructed to investigate the influence of the ironing reduction, velocity and die angle on the process forces and friction. Furthermore, an in-situ study of the displacement and strain fields has been performed in the strip ironing experiments using a digit image correlation technique. Simulations of the process have been performed using an arbitrary Lagrange Euler method based on an operator splitting procedure (OS-ALE). The constitutive behavior of metal and polymer has been modeled wiht a generalized impressible Leonov model with a Bodner-Partom and an Eyring viscosity function, respectively. The experimental results are in good agreement with numeric simulations.