Flange projection control system and method

A blank and draw punch for forming cups, the blank and draw punch comprising:

• a blank and draw punch base;
• and
• a blank and draw punch cylindrical portion extending from the blank and draw punch base, the blank and draw punch cylindrical portion comprising:
• a blank and draw punch inner circumferential wall defining a blank and draw punch cavity;
• a blank and draw punch proximal surface extending substantially perpendicular to the blank and draw punch inner circumferential wall;
• and
• a blank and draw punch curved edge disposed between the blank and draw punch inner circumferential wall and the blank and draw punch proximal surface, the blank and draw punch curved edge having a radius of curvature that varies along its circumference.

A draw-redraw die configured to redraw a cup to form a can, the draw-redraw die comprising:

• a draw-redraw die base;
• and
• a draw-redraw die cylindrical portion extending from the draw-redraw die base, the draw-redraw die cylindrical portion comprising:
• a draw-redraw die inner circumferential wall defining a draw-redraw die cavity;
• a draw-redraw die proximal surface extending substantially perpendicular to the draw-redraw die inner circumferential wall;
• and
• a draw-redraw die curved edge disposed between the draw-redraw die inner circumferential wall and the draw-redraw die proximal surface, the draw-redraw die curved edge having a radius of curvature that varies along its circumference.

A die assembly for forming containers, the die assembly having a plurality of tooling stations, each tooling station comprising:

• (i) a blank and draw punch configured to blank off a portion of stock from a stock element and draw the portion of stock to form a cup, the blank and draw punch comprising:
• a blank and draw punch inner circumferential wall defining a blank and draw punch cavity;
• a blank and draw punch proximal surface extending substantially perpendicular to the blank and draw punch inner circumferential wall;
• and
• a blank and draw punch curved edge disposed between the blank and draw punch inner circumferential wall and the blank and draw punch proximal surface, the blank and draw punch curved edge having a radius of curvature that varies along its circumference;
• and
• (ii) a draw-redraw die configured to redraw the cup to form a can having a flange, the draw-redraw die comprising:
• a draw-redraw die inner circumferential wall defining a draw-redraw die cavity;
• a draw-redraw die proximal surface extending substantially perpendicular to the draw-redraw die inner circumferential wall;
• and
• a draw-redraw die curved edge disposed between the draw redraw die inner circumferential wall and the draw-redraw die proximal surface, the draw-redraw die curved edge having a radius of curvature that varies along its circumference.

A method of forming containers comprising:

• receiving a stock element at a tooling station having a blank and draw punch comprising a blank and draw punch curved edge disposed between a blank and draw punch inner circumferential wall and a blank and draw punch proximal surface, the blank and draw punch curved edge having a radius of curvature that varies along its circumference;
• blanking off a portion of stock from the stock element using the blank and draw punch;
• and
• forming, via the blank and draw punch, a cup from the portion of stock by drawing the portion of stock across tangent points of the varied radius of curvature of the blank and draw punch curved edge.

A method of forming containers comprising:

• receiving a stock element at a tooling station having a blank and draw punch comprising a blank and draw punch curved edge disposed between a blank and draw punch inner circumferential wall and a blank and draw punch proximal surface, the blank and draw punch curved edge having a radius of curvature that varies along its circumference;
• blanking off a portion of stock from the stock element using the blank and draw punch;
• moving, at the tooling station, the blank and draw punch and a draw-redraw die from an open position to a cup forming position, the draw-redraw die having a draw-redraw die curved edge disposed between a draw-redraw die inner circumferential wall and a draw-redraw die proximal surface;
• forming, between the blank and draw punch and the draw-redraw die at the tooling station, a cup from the portion of stock by drawing the portion of stock across tangent points of the varied radius of curvature of the blank and draw punch curved edge;
• moving, at the tooling station, the blank and draw punch and the draw-redraw die to a can forming position;
• and
• forming, via the draw-redraw die at the tooling station, a can having a flange from the cup by redrawing the formed cup across tangent points of the varied radius of curvature of the draw-redraw die curved edge.

A method of forming containers comprising:

• receiving a stock element at a plurality of tooling stations of a die assembly, each of the plurality of tooling stations having a blank and draw punch comprising a blank and draw punch curved edge disposed between a blank and draw punch inner circumferential wall and a blank and draw punch proximal surface, the blank and draw punch curved edge having a radius of curvature that varies along its circumference;
• blanking off a portion of stock from the stock element using the blank and draw punch at each tooling station;
• moving, at each tooling station, the blank and draw punch and a draw-redraw die from an open position to a cup forming position, each draw-redraw die having a draw-redraw die curved edge disposed between a draw-redraw die inner circumferential wall and a draw-redraw die proximal surface;
• forming, between the blank and draw punch and the draw-redraw die at each tooling station, a cup from the portion of stock by drawing the portion of stock across tangent points of the varied radius of curvature of the blank and draw punch curved edge;
• moving the blank and draw punch and the draw-redraw die at each tooling station to a can forming position;
• and
• forming, at each tooling station, a can having a flange from the cup by redrawing the formed cup across tangent points of the varied radius of curvature of the draw-redraw die curved edge.

A double action tooling station for forming containers, comprising:

• (i) an outer slide comprising a blank and draw punch configured to blank off a portion of stock from a stock element and apply draw pressure, the blank and draw punch comprising:
• a blank and draw punch inner circumferential wall defining a blank and draw punch cavity;
• a blank and draw punch proximal surface extending substantially perpendicular to the blank and draw punch inner circumferential wall;
• and
• a blank and draw punch curved edge disposed between the blank and draw punch inner circumferential wall and the blank and draw punch proximal surface, the blank and draw punch curved edge having a radius of curvature that varies along its circumference;
• and
• (ii) an inner slide comprising a draw punch configured to draw the portion of stock to form a cup, the draw punch comprising:
• a punch center having a radius of curvature that varies along its circumference;
• wherein the outer slide is configured to move independently of the inner slide.