Cold nosing process modeling and simulation for manufacturing of aluminium conical milk can

The modeling and simulation methods for the manufacturing systems of conical milk cans are proposed. The processes adopted in this manufacturing system are divided into three stages: backward cup extrusion, ironing of the can body, and neck nosing of the can. The most crucial stage of this manufacturing system is the nosing process which usually takes many steps, vary from three to ten, to form the final shape and dimension precisely. The modeling of the maximum nosing rate is proposed to determine the steps required to make the can in the nosing stage. The conic curve model is proposed to design the nosing dies to minimize the nosing steps and obtain smoother material flow of forming process. Three-dimensional FEM simulations were carried out to evaluate the proposed die profile designs and validate the manufacturing system. The geometrical parameters of the proposed conic curves of die profile are optimized via the DOE method. The FEM simulation results show that the proposed die profile design method is capable of preventing the buckling defects and reducing the steps of nosing to three.