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Formability of Polymer-coated Metals / WOLFRAM REINHARDT

Swansea University Author: WOLFRAM REINHARDT

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DOI (Published version): 10.23889/SUthesis.59734

Abstract

This project was undertaken to explore the viability of manufacturing polymer-coated cans using current drawing-wall-ironing methods, and centres around exploring polymer-coated alternatives to lacquered food and beverage cans. A full process FEA model was developed in Abaqus, and a polymer coating...

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Published: Swansea 2021
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Harrison, Will
URI: https://cronfa.swan.ac.uk/Record/cronfa59734
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first_indexed 2022-03-29T11:48:13Z
last_indexed 2022-03-30T03:27:46Z
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spelling 2022-03-29T13:03:30.3077882 v2 59734 2022-03-29 Formability of Polymer-coated Metals 9c82eb89276ea5d7afe5acf75aca3e1f WOLFRAM REINHARDT WOLFRAM REINHARDT true false 2022-03-29 This project was undertaken to explore the viability of manufacturing polymer-coated cans using current drawing-wall-ironing methods, and centres around exploring polymer-coated alternatives to lacquered food and beverage cans. A full process FEA model was developed in Abaqus, and a polymer coating characterisation was attempted via tensile and compressive tests of available PET. As an alternative, the polymer was modelled as a force/over-closure con-tact definition in finite element analysis models, using force data derived from existing polymer data. The contact definition demonstrated an effective alter-native to modelling a finite element meshed polymer layer but needed opti-mising to match physical results. A tensile test machine rig was designed and manufactured capable of ironing strip metal specimens for otherwise unavail-able ironing metrology. The rig was calibrated using uncoated steel, then used to gain data on force and resulting geometry for polymer coated steel during and after ironing. Rig data was used in a finite element analysis automated feedback loop to optimise the force/over-closure and friction coefficients for the contact definition. Finally, a full-process drawing-wall-ironing simulation on polymer coated steel was implemented in a design of experiments study, which mapped the previously unexplored design space. The most significant parameters in resulting can geometry were the percentage of redraw and iron-ing during the respective forming phases, as well as the redraw radius. De-creasing the diameter of both redraw and ironing tooling rings resulted in a longer and thinner can, as did decreasing the redraw radius. Whilst not an ex-haustive study, the project ultimately demonstrated the viability of modelling polymer-coatings using contact definitions in finite element analysis and paves the way for further study into the polymer-coated steel can. E-Thesis Swansea Computational analysis, experimental procedure, FEA, Abaqus, Processing, manufacturing, drawing, wall ironing 16 7 2021 2021-07-16 10.23889/SUthesis.59734 COLLEGE NANME COLLEGE CODE Swansea University Harrison, Will Doctoral EngD Crown Packaging PLC; European Social Fund (ESF) 2022-03-29T13:03:30.3077882 2022-03-29T12:44:56.5213902 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised WOLFRAM REINHARDT 1 59734__23721__4df8207b7adc403ca9a51ebae9d09860.pdf Reinhardt_Wolfram_EngD_Thesis_Final_Cronfa.pdf 2022-03-29T13:02:41.7093084 Output 4583859 application/pdf E-Thesis – open access true Copyright: The author, Wolfram Reinhardt, 2021. true eng
title Formability of Polymer-coated Metals
spellingShingle Formability of Polymer-coated Metals
WOLFRAM REINHARDT
title_short Formability of Polymer-coated Metals
title_full Formability of Polymer-coated Metals
title_fullStr Formability of Polymer-coated Metals
title_full_unstemmed Formability of Polymer-coated Metals
title_sort Formability of Polymer-coated Metals
author_id_str_mv 9c82eb89276ea5d7afe5acf75aca3e1f
author_id_fullname_str_mv 9c82eb89276ea5d7afe5acf75aca3e1f_***_WOLFRAM REINHARDT
author WOLFRAM REINHARDT
author2 WOLFRAM REINHARDT
format E-Thesis
publishDate 2021
institution Swansea University
doi_str_mv 10.23889/SUthesis.59734
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 1
active_str 0
description This project was undertaken to explore the viability of manufacturing polymer-coated cans using current drawing-wall-ironing methods, and centres around exploring polymer-coated alternatives to lacquered food and beverage cans. A full process FEA model was developed in Abaqus, and a polymer coating characterisation was attempted via tensile and compressive tests of available PET. As an alternative, the polymer was modelled as a force/over-closure con-tact definition in finite element analysis models, using force data derived from existing polymer data. The contact definition demonstrated an effective alter-native to modelling a finite element meshed polymer layer but needed opti-mising to match physical results. A tensile test machine rig was designed and manufactured capable of ironing strip metal specimens for otherwise unavail-able ironing metrology. The rig was calibrated using uncoated steel, then used to gain data on force and resulting geometry for polymer coated steel during and after ironing. Rig data was used in a finite element analysis automated feedback loop to optimise the force/over-closure and friction coefficients for the contact definition. Finally, a full-process drawing-wall-ironing simulation on polymer coated steel was implemented in a design of experiments study, which mapped the previously unexplored design space. The most significant parameters in resulting can geometry were the percentage of redraw and iron-ing during the respective forming phases, as well as the redraw radius. De-creasing the diameter of both redraw and ironing tooling rings resulted in a longer and thinner can, as did decreasing the redraw radius. Whilst not an ex-haustive study, the project ultimately demonstrated the viability of modelling polymer-coatings using contact definitions in finite element analysis and paves the way for further study into the polymer-coated steel can.
published_date 2021-07-16T04:17:16Z
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score 11.013082

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