An economical and environmental alternative to traditional can - - PowerPoint PPT Presentation

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Jun 17, 2023 99 likes •315 views

An economical and environmental alternative to traditional can manufacturing using a new pre-laminated steel Miguel ngel Sells Cant, Steven R. Schmid, Samuel Snchez Caballero, Maziar Ramezani, Elena Prez Bernabeu Outline

SLIDE 1

An economical and environmental alternative to traditional can manufacturing using a new pre-laminated steel

Miguel Ángel Sellés Cantó, Steven R. Schmid, Samuel Sánchez Caballero, Maziar Ramezani, Elena Pérez Bernabeu

SLIDE 2

Outline

 Introduction  Theoretical modelization  Experimental  Results  Conclusions

SLIDE 3

Context

I n t r

u c t i

Introduc Introduction tion 3 Source: MarketsandMarkets.com

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Steps in can manufacturing

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Introduc Introduction tion 4 Metal coil Sheet metal is lubricated and small discs are cutted Drawing, Redrawing, Ironing Doming Cutting Wash and dry Lubricant removal External coating Base for ink Coating drying on a furnace External decoration Decoration drying Sprayed internal coating Internal coating drying Necking

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Alternative of a precoated sheet

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Introduc Introduction tion 5

Advantages:  Reduction of manufacturing steps.  Reduction of time in the manufacturing cycle.  Reduction of costs. Disadvantages:  More expensive material.  Possible damage to polymer layers.

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Reduction of steps in can manufacturing

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Introduc Introduction tion 6 Lubrication Washing and drying Coating drying Coating drying External coating Internal coating

X X X X X X

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Objective of this research

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Introduc Introduction tion 7

 Study the processability in the use of a steel sheet coated with two polymer layers.  Carry out a theoretical model of the optimum process conditions.  Validate this model with experiments on an ironing simulator.  If viability is demonstrated, it would be possible:

manufacture

metal containers without VOCs emissions ⇒ environmental improvement.

a greater internal insulation between beverage and metal.

improve the mechanical properties of can.

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Material characteristics

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Introduc Introduction tion 8

 Material provided by ArcelorMittal.

Tie layer: Characteristics of maximum adhesion to metal. Top layer: Characteristics of high strength and good mechanical properties. Good properties for friction.

Steel Tie layer Top layer

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Ironing

Theoreti Theoretical Mo cal Model del

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e t i c a l M

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 It’s the most crucial step in a polymer-coated can manufacturing.  Variables:

 Mat

Materi erial al

 Tem

Temper peratu ature re

 Die

Die an angle gle

 Red

Reduct uction ion in thi thickn ckness ess

 Pun

Punch ch vel veloc

city

ity

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Upper bound: Successful ironing

Theoreti Theoretical mo cal model del

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Upper bound: Shaving

Theoreti Theoretical Mo cal Model del

T h e

e t i c a l M

e l

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Artificial Neural Network of Ironing

Theoreti Theoretical Mo cal Model del

T h e

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e l

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Ironing Simulator

E x p e r i m e n t a l

Experime Experimental ntal 13

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Design of experiments

E x p e r i m e n t a l

Experime Experimental ntal 14

Process variables Levels

Die angle º 2 4 6 8 10 Punch velocity m/s 0,5 0,75 1 Reduction % 5 10 15 20 Die temperature ºC 25 100

 D-optimal design  Design ExpertTM

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Theoretical results

R e s u l t s

Results Results 15

Φ ≈ 4.8º

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Surface Quality Factor (SQF)

R e s u l t s

Results Results 16 NO IRONING SQF=0 SQF=2 SQF=4 SQF=8 SQF=10

 It’s a qualitative factor.  Surfaces are compared to the following ones:

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Surface Quality Factor (SQF)

R e s u l t s

Results Results 17

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Roughness

R e s u l t s

Results Results 18

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Conclusions

 Die angle is the most important variable. Good ironings have been achieved with angles of 6º or lower.  Punch speed and temperature have less significancy over the ironing quality.  Experimental results are very close to those obtained with the theoretical upper bound models.  The new 2 layer-polymer coated material survived to the most critical step in can manufaturing (ironing), under certain conditions.  Several steps in traditional can manufacturing can be eliminated: reduces cost and benefits environment.

c l u s i

Conclusi Conclusions

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Thank you for your attention

maselles@dimm.upv.es steve.schmid@uncc.edu sasanca@dimm.upv.es maziar.ramezani@aut.ac.nz elenapb@eio.upv.es