Understanding and Troubleshooting Splits in Bodymaker Machines

Introduction

In the aluminum can production process, bodymaker machines play a crucial role in shaping and forming the cans. However, defects may occur during the production process, causing issues in the final product. One such defect is known as “Splits,” which can lead to significant production losses and quality concerns. This article will discuss the causes, symptoms, and remedies for Splits in bodymaker machines.

Causes of Splits in Bodymaker Machines

Splits can occur due to various factors, including misaligned tooling, improperly ground dies, and material build-up on the punch. These factors can lead to uneven can heights, which are a common symptom of Splits.

1. Misalignment of tooling: If the tooling components in the bodymaker machine are not correctly aligned, it can cause uneven pressure distribution during the forming process, leading to Splits.
2. Improperly ground dies: Dies that are not properly ground can create uneven surfaces and pressure points during the can forming process, increasing the likelihood of Splits.
3. Material build-up on the punch: Over time, material can accumulate on the punch, causing uneven pressure distribution and, ultimately, Splits.

Symptoms of Splits in Bodymaker Machines

The primary symptom of Splits in bodymaker machines is uneven can heights. This can be observed by visually inspecting the cans produced by the machine and looking for inconsistencies in height.

Another symptom is the presence of defects in the formed cans, which can be seen with the naked eye or using a quality control microscope. These defects may be located relative to the height of the can, the identification mark on the bottom, and the rolling direction of the metal.

Remedies for Splits in Bodymaker Machines

To address the issue of Splits in bodymaker machines, the following remedies can be implemented:

1. Re-align the tooling: Ensuring proper alignment of the tooling components can help distribute pressure evenly during the forming process, reducing the likelihood of Splits.
2. Return dies to the toolroom: If the dies are improperly ground, they should be returned to the toolroom for re-grinding or replacement to ensure a smooth forming process.
3. Polish or replace the punch: If material build-up is observed on the punch, it should be polished or replaced to prevent uneven pressure distribution and Splits.

Conclusion

Splits in bodymaker machines can lead to significant production losses and quality concerns. By understanding the causes, symptoms, and remedies for this defect, manufacturers can take proactive measures to minimize the occurrence of Splits and maintain the quality of their aluminum cans. Regular inspection and maintenance of the bodymaker machines are crucial to ensure smooth and efficient production processes.