A Numerical and Experimental Analysis of the Mechanical Behavior of the Aluminum Beverage Can with Internal Varnish Layers during Axial Load Force Testing.

This article presents a numerical and experimental investigation into the impact of can wall thickness and the internal varnish layer thickness on the results of an axial load force test. This study also shows the levels of thermal stresses that emerge after the drying of varnish coating, and how they affect the results of the axial load force test. This research involves the development of suitable numerical models and the experimental acquisition of stress-deformation relationships for the both can material, aluminum, and the varnish. The numerical simulation of the axial load force test has been verified through experimental tests, with a resulting difference of 8.9% between the two sets of results. The findings highlight that changes in the can wall thickness have a more pronounced effect on test outcomes compared to variations in the varnish thickness. Specifically, an increase in the can wall thickness from 90 µm to 100 µm results in a substantial 116 N increase in the force required for a can to collapse. Nevertheless, the presence of a 5 µm varnish layer also contributes measurably, increasing the can's collapse force by 21 N. These results offer valuable practical insights for manufacturers, enabling them to effectively optimize can strength characteristics.

A Flow Stress Model of the AA3104-H19 Alloy for the FEM Simulation of the Beverage Can Manufacturing Process under Large Plastic Deformations.

This paper discusses the development of a flow stress model to simulate the AA3104-H19 alloy under the conditions of large plastic deformations characteristic of the beverage can manufacturing process. This study focuses on the first five steps of this process: cupping, redrawing, ironing #1, ironing #2, ironing #3. These are the stages that reduce the thickness of the base material to the maximum, resulting in an effective strain of more than 2.0, unattainable in conventional plastometric tests. To solve this problem, the specific calculation-experimental method for the development of the flow stress model was proposed. Based on the FEM modeling of the technological process, data on the history of deformation and the trajectory of movement of the selected points of the material at all stages of the production were obtained. Microspecimens for the tensile tests were taken from the points of the beverage can wall that were determined in this way. The initial strain of each sample was taken from the FEM simulation. In this way, the tensile curves were obtained for the material points at different stages of the production. The processing of these curves allowed the creation of a flow stress model for large strains, corresponding to production conditions. The tensile tests were performed on a Zwick Z250 machine at room temperature and strain rate of 0.005 s-1. The FEM-based algorithm for the determination of empirical coefficients of the analytical flow stress model is presented. The final flow stress model covers the range of effective strain from 0-2. Validation of the developed model based on the measured beverage can thicknesses showed that a flow stress model was developed that correctly and accurately describes the forming process.

Microstructure and In Vitro Evaluation of Extruded and Hot Drawn Alloy MgCa0.7 for Biodegradable Surgical Wires.

The MgCa0.7 alloy may be a promising material for biodegradable surgical wires. In this paper, the technology for producing surgical wires from this alloy has been developed, based both on finite element modelling and experimental study. In particular, the extrusion and hot-drawing effects on the mechanical properties, microstructures, in-vitro rates of biocorrosion, and cytotoxicity to human cancer cells (SaOS-2) and healthy (hPDL) ones, have been determined. An approximately 30-40% increase in corrosion rate due to increasing hot-drawing temperature was observed. An effect of hot-drawing temperature on cytotoxicity was also found. Notably, at various stages of the final wires' production, the MgCa0.7 alloy became toxic to cancer cells. This cytotoxicity depended on the alloys' processing parameters and was maximal for the as-extruded rod and for the wires immediately after hot drawing at 440 °C. Thus, the careful selection of processing parameters makes it possible to obtain a product that is not only a promising candidate for biodegradable surgical wires, but one which also has intrinsic bioactive properties that produce antitumor activity.

Experimental and Numerical Study of Surface Roughness of Thin Brass Wire Processed by Different Dieless Drawing Processes.

This paper examines the surface roughness of a thin brass wire (140-200 microns in diameter) after two dieless drawing (DD) processes, i.e., conventional dieless drawing (CDD) and incremental dieless drawing (IDD). In incremental dieless drawing, small increments in deformation were applied in several passes. It has been proven that the IDD process not only has a greater efficiency but also enables obtaining a wire with significantly lower surface roughness. The explanation for these effects is based on the results of the numerical modeling of both compared processes. The developed numerical model takes into consideration the initial roughness of the wire surface, shape and dimensions of grains, and their diversified mechanical properties. Nanoindentation measurements, microstructure, and plastometric studies allowed us to find the effective flow stress distribution in the grains. The IDD process was found to be much more stable and develop a much more uniform distribution of grain strain than the CDD process. More homogeneous deformation results in surface roughness reduction. Approximately 25-30% reduction in surface roughness of the wire produced by the IDD process was predicted by simulations and confirmed experimentally.