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.

The Impact of Temperature Conditions on the Manufacturing Process and Mechanical Behavior of Beverage Can Ends during Operation.

This article investigates the impact of temperature regimes, corresponding to various climatic zones, on the manufacturing process and operation of beverage can ends made of aluminum alloy AA5182. The production process of aluminum beverage can ends involves multiple steps, including melting, rolling, and stamping, where different temperatures can influence both the production process and the properties of the final product. Furthermore, the mechanical behavior of the final product is affected by the aging process of alloy AA5182, which progresses at varying rates depending on the temperature conditions during storage. The objective of this study is to simulate the production process under various climatic conditions using the finite element method (FEM) and experimentally investigate the dependence of the strength of alloy AA5182 can ends on storage time and temperature. The findings of the study reveal that, under temperature conditions corresponding to warmer climates, the punching force can be reduced by approximately 15% compared to production in colder climates. Additionally, the strength of the finished can exhibits a decrease of about 10% during a month of storage in a warm climate, while no significant decrease was observed in colder climates. These results hold practical significance for the beverage production industry, as the manufacturing and operation of beverage cans are localized in diverse climatic zones.

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.

In vitro cytotoxicity of biodegradable Zn-Mg surgical wires in tumor and healthy cells.

In this work, we examined the in vitro cytotoxicity of new biodegradable surgical wires. The wires made of zinc with the addition of a small amount of magnesium (pure zinc, ZnMg 0.0026, ZnMg 0.0068, and ZnMg 0.08) have been investigated. The wires were produced using a technology based on extrusion and subsequent drawing. The resulting wires with a diameter of 0.8-1.0 mm are designed to be used in surgical operations related to bone joints. For cytotoxicity studies, we have selected human dental pulp stem cells (hDPSC) as the cell population representing normal osteoprogenitor cells. Considering that, after bone surgeries, the chance of osteosarcoma increases, we have compared the results obtained in hDPSC to those obtained with Saos-2 human osteosarcoma cell line. Cultured cells were exposed to the extracts obtained from the materials incubated in culture medium for 24 h with and without preincubation. Extracts of different ratios were examined. The results showed that the extracts obtained from wires made of ZnMg 0.0026 alloy exhibit high toxicity to Saos-2 osteosarcoma cells and low toxicity to hDPSC cells. This was in contrast to all reference materials, i.e., commercial surgical sutures made of steel and polymers, that did not display cytotoxicity toward osteosarcoma cells. Thus, the detected phenomenon for the ZnMg 0.0026 alloy can become the basis for creating biodegradable Zn-Mg surgical wires with antitumor activity.

Digital image correlation of coated and uncoated Religa Heart_Ext ventricular assist device.

The digital image correlation is used to estimate influence of deposited heamocompatible coatings (gold and titanium nitride) on mechanical response of ventricular assist device Religa Heart_Ext made of Bionate II (thermoplastic polycarbonate urethane) under working conditions by comparison of the coated Religa Heart_Ext with uncoated Religa Heart_Ext. The DIC is applied for experimental investigation of the strains and displacements distribution on external surface of the blood chamber of ventricular assist device during loading. The experiment was conducted in a hydraulic system with water at operating temperatures of 25 and 37 °C, as well as under static pressures: 80, 120, 180, 220 and 280 mmHg, and static underpressures: -25, -45, -75 mmHg. The subsequent images were taken after stabilization of pressure on a set level. The applied research method shows that the nano-coating of 30 nm in thickness significantly affects deformation of the blood chamber of Religa Heart_Ext in macro scale. The proposed composition of coatings increases strain on external surface of the ventricular assist device.