Method for forming a deep draw closure cap

A method for forming a deep draw closure cap structured to be positioned over an upper end of a bottle, the method comprising:

• draw forming a first cup from a planar sheet of a metal material defining a base thickness, wherein the first cup comprises a first cup base, a first cup wall, and an open end;
• performing a first redrawing of the first cup to form a first redrawn cup comprising a first redrawn cup base, a first redrawn cup wall, and an open end;
• passing the first redrawn cup through an ironing die to reduce a thickness of the first redrawn cup wall adjacent to the open end to be less than a thickness of the first redrawn cup wall adjacent to the first cup base;
• providing second redraw tooling including a second redraw die, a second redraw pad, and a second redraw punch movable between an extended position cooperating with the second redraw die and a retracted position;
• and
• performing a second redrawing of the first redrawn cup with the second redraw tooling, wherein the second redrawing occurs after the first redrawing and before passing the first redrawn cup through the ironing die to form a second redrawn cup having a cup base, a cup wall, and an open end, the second redrawing comprising,
• engaging a portion of the redrawn cup base between the second redraw pad and the second redraw die, and
• moving the second redraw punch to the extended position to draw material of the redrawn cup through the second redraw die,
• wherein the performing the first redrawing is done using first redraw tooling, wherein the first redraw tooling comprises a first redraw die, a first redraw pad, and a first redraw punch movable between an extended position cooperating with the first redraw die and a retracted position,
• wherein a portion of the first cup base is engaged between the first redraw pad and the first redraw die, wherein a predetermined first force acts on the first cup base,
• wherein the first redraw pad cooperates with the first redraw die for constraining the metal material of the first cup to bend across a radius of the first redraw die, and wherein the first redraw punch is moved to the extended position to draw the metal material of the first cup through the first redraw die and define the redrawn cup wall, and
• wherein movement of at least one of the first redraw punch and the second redraw punch comprises cooperation with at least one of the first and second redraw die to perform a pinch trim on the metal material adjacent to an open end of at least one of:
• (1) the redrawn cup;
• and (2) the second redrawn cup.