Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: In hydroforming of hollow metal articles in a die, such as pressure-ram-forming procedures, a method of decreasing cycle time of the forming process, while ensuring acceptable product properties and avoiding failures, by modeling the process using finite element analysis to establish a pressure-time history that optimizes the forming operation and applies failure limits to selected variables such as minimum wall thickness or maximum strain rate, and transferring this pressure-time history to a computer controlling the forming process. Thermocouple and/or continuity sensors are incorporated into the die wall and connected to the computer so as to provide active feedback from the die to the control of the process.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity (10) defining the desired shape, and advancing a punch (12) into the die cavity (10) to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: A method of developing a can (e.g. beverage) bottom profile is presented. More specifically, finite element analysis on a parametric representation of a beverage can is used for developing an improved beverage can design. By specifying performance parameters that the beverage can must meet and providing specific geometric limitations on the design an improved beverage can design is obtained. The resulting improved beverage can design is independent of the gauge of the material used in construction thereof. The improved beverage can provides a concave dome on the bottom of the can connected to a bottom stand which in turn is connected to a cylindrical side wall of the can via a slanted connecting wall.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch into the die cavity to displace and deform the closed end of the preform after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate.

Abstract: A method of spin forming an open-ended container or other cylindrical metal workpiece by inserting a conically tapering mandrel coaxially therein and pressing the side wall of the workpiece against the inserted mandrel with plural symmetrically arranged forming discs while unidirectionally translating the workpiece, and independently translating the mandrel, relative to the forming discs.