Forming of Multifunctional Corrugated Cup Using Roller Ball Die

To produce functional cups by press forming, clad cups with a corrugated structure with voids like the cross section of corrugated cardboard were formed. Deep drawing, which is one type of press forming, is a plastic processing technology that forms thin sheets into three-dimensional containers. In the experiment, pure titanium TP270 and ultra-low carbon steel SPCC were used as test materials. The blank sheet thickness was 0.3 mm and the diameter was 80 mm to 90 mm. To form the corrugated cup, the roller ball die with steel balls installed on the shoulder of the die was prototyped. The steel balls were made of bearing steel JIS-SUJ2 and had diameters of 6.4 mm and 7.5 mm. The corrugated clad cup was formed by the composite die combined with a conventional die. Three conventional dies and two roller ball dies were used to obtain two corrugated layers with voids. The lubricant was a tool oil containing molybdenum disulfide powder. The sheet thickness strain distribution and residual stress distribution of the cup were evaluated. No destruction of the cup occurred during deep drawing. A regular wavy structure was observed in the cross section of the cup. The maximum reduction in the cup thickness was approximately 10 %. The residual stress on the outside of the cup was tensile stress from the bottom to the opening of the cup. The composite die made it possible to form a functional cup.