Devices and methods configured to manipulate friction between a working piece and a deep drawing tool in a deep drawing process

Abstract

Described are techniques and systems for improving the reliability of metal forming operations, such as stamping or drawing processes. Lubricants that can have their lubricating properties changed in real time through the application of an electric current are used to modify the friction between the forming equipment and the metal product being formed, allowing for more precise control over forming and associated operations.

What is claimed is: 
     
         1 . A system for making a metal product, comprising:
 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, wherein 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 and while the metal product is being ejected from the punch.   
     
     
         2 . The system of  claim 1 , wherein 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. 
     
     
         3 . A container manufacturing system, comprising:
 a cylindrical ram comprising a ram body and a ram nose on a distal end of the ram body, the ram nose engagable with a base of a container preform;   a die comprising an opening concentrically aligned with the cylindrical ram, the opening sized and shaped for receiving the container preform in response to the ram nose engaging with the base of the container preform and the cylindrical ram driving the container preform through the die opening; and   an ultrasonic device coupled with the die, wherein the ultrasonic device causes the die to vibrate while the cylindrical ram drives the container preform through the die opening.   
     
     
         4 . The container manufacturing system of  claim 3 , wherein the die is a first die and the container manufacturing system further comprises a second die having an opening for receiving the container preform and concentrically aligned with the opening of the first die and the cylindrical ram. 
     
     
         5 . The container manufacturing system of  claim 4 , wherein the ultrasonic device is a first ultrasonic device and the container manufacturing system further comprises a second ultrasonic device coupled with the second die causing the second die to vibrate while the cylindrical ram drives the container preform through the second die opening. 
     
     
         6 . A method of forming an aluminum container, comprising:
 receiving, on a ram, a container preform comprising a base and sidewalls, the base of the container preform engaged with a distal end of the ram;   vibrating a die using an ultrasonic device connected to the die, the die having an opening concentrically aligned with the ram and sized and shaped for receiving the container preform; and   driving the container preform through the die opening by moving the ram in a linear direction through the die opening.   
     
     
         7 . The method of  claim 6 , wherein the ultrasonic device vibrates the die in an axial direction or wherein the ultrasonic device vibrates the die in a radial direction. 
     
     
         8 . The method of  claim 6 , further comprises retracting the ram through the die opening, wherein the ultrasonic device vibrates the die in a first direction when driving the container preform through the die opening and vibrates the die in a second direction when retracting the ram. 
     
     
         9 . A die for forming an aluminum container, comprising:
 a body defining a die opening sized and shaped for receiving a container preform in response to the container preform being driven by a ram through the die opening; and   an ultrasonic device coupled with the die for causing the die to vibrate while the container preform is being driven through the die opening by the ram.   
     
     
         10 . The die of  claim 9 , wherein the ultrasonic device is a first ultrasonic device and the die further comprises a second ultrasonic device coupled with the die for causing the die to vibrate. 
     
     
         11 . The die of  claim 10 , wherein the first ultrasonic device causes the die to vibrate in a first direction and the second ultrasonic device causes the die to vibrate in a second direction.