The Ingenious Design of the Aluminum Beverage Alüminyum İçeceklerin dahiyane tasarımı

the ingenious design of the aluminum beverage gap every year nearly a half trillion of these cans are manufactured that’s about 15,000 per second so many that we overlook the cans superb engineering let’s start with why the cam is shaped like it is why a cylinder an engineer might like to make a spherical can it has the smallest surface area for a given volume and so it uses the least amount of material and it also has no corners and so no weak points because the pressure in the can uniformly stresses the walls but a sphere is not practically manufactured and of course it’ll roll off the table also when packed as closely as possible only 74% of the total volume is taken up by the product the other 26% is void space which goes unused when transporting the cans or in a store display an engineer could sell this problem by making a cuboid shaped cam it sits on a table but it’s uncomfortable to hold and awkward to drink from and well easier to manufacture those sphere these edges are weak voids and require very thick walls but the cuboid surpasses the sphere and packing efficiency it is almost no wasted space although with the sacrifice of using more surface area to contain the same volume as the sphere so to create a can engineers use a cylinder which has elements of both shapes from the top it’s like a sphere and from the side it’s like a cuboid a cylinder has a maximum packing factor of about 91 percent not as good as the cuboid bit better than the sphere most important of all the cylinder can be rapidly manufactured the can begins as this disc called a blank punch from an aluminum sheet about three tenths of a millimeter thick the first step starts with a drawing guy on which sits the blank and then a blank holder that rests on top well look at a slice of the die so we can see what’s happening a cylindrical punch presses down on the die forming the blank into a cup this process is called drawing this cup is about 88 millimeters in diameter larger than the final can so its redrawn that process starts with this white cup and uses another cylindrical punch and a redrawing die the punch presses the cup through the redrawing die and transforms it into a cup with a narrower diameter which is a bit taller this redrawn Cup is now the final diameter of the can 65 millimeters but it’s not yet tall enough a punch pushes this redrawn Cup through an ironing ring the cup stays the same diameter as it becomes taller on the walls thinner if we watch this process again up close you see the initial thick wall and then the thinner wall after it’s ironed ironing occurs in three stages each progressively making the walls thinner and the kam taller after the cup is iron the dome on the bottom is formed this requires a convex doming tool and a punch with a matching concave indentation as the punch presses the cup downward into the doming tool the cup bottom then deforms into a dome that dome reduces the amount of metal needed to manufacture the can the dome bottom uses less material than if the bottom were flat a dome is an arch revolved around its inner the curvature of the arch distributes some of the vertical load into horizontal forces allowing a dome to withstand greater pressure than a flat beam on the dome you might notice two large numbers these debossed numbers are engraved on the doming tool the first number signifies the production line in the factory and the second number signifies the body maker number the body maker is the machine that performs the redrawing ironing and doming processes these numbers help troubleshoot production problems in the factory in that factory the manufacturing of can takes place at a tremendous rate these last three steps redrawing ironing and doming all happen in one continuous stroke in an only ¹⁄₇ of a second the punch moves at a maximum velocity of 11 meters per second and experiences a maximum acceleration of 45 G’s this process runs continuously for six months or around a hundred million cycles before the machine needs servicing now if you look closely at the top of the cam body you see that the edges are wavy and uneven these irregularities occurred during the forming to get a nice even edge about six millimeters is trimmed off at the top with an even top and could now be sealed but before that sealing occurs a colorful design is printed on the outside the term of art in the industry is a decoration the inside also gets a treatment a spray coated epoxy lacquer separates the cans contents from its aluminum walls this prevents the drink from acquiring the metallic taste and also keeps acids in the beverage from dissolving the aluminum the next step forms the cans neck the part of the can body that tapers inward this necking requires eleven stages the forming starts with a straight walled cannon the top is brought slightly inward and then this is repeated further up a Ken wall until the final diameter is reached the change in neck size at each stage is so subtle that you can barely tell a difference between one stage in the next each one of these stages works by inserting an inner die into the can body then pushing an outer dyeing called the necking sleeve around the outside the necking sleeve attracts the inner diary tracks and the can moves to the next stage the neck has drawn out over many different stages to prevent wrinkling or pleading of the thin aluminum since the 1960’s the diameter of the cannon has become smaller by six millimeters from 60 millimetres to 54 millimeters today this seems a tiny amount but the aluminum can industry produces over 100 billion cans a year so that six millimeter reduction saves at least 90 million kilograms of aluminum annually that amount would form a solid cube of aluminum 32 meters on a side compare that to a 787 dreamliner with a 60 meter wingspan now after the neck has been formed the top is flanged that is it flares out slightly and allows the end to be secured to the body which brings us to the next brilliant design feature the double seam on older steel cans manufacturers welded or soldered on the ends this often contaminated the cans contents in contrast today’s cans use a hygienic devil seam which can also be made faster this can is cut in half so you can see the cross section of the devil seam to create this scene a machine uses two basic operations the first curls the end of the can cover around the flange of the can body the second operation presses the folds of the metal together to form an airtight seal well the operation themselves are simple they require high precision parts misaligned by a small fraction of a millimeter caused the seam to fail in addition to the clamping of the end can body a sealing compound ensures that no gas escapes through the devil’ seen the compound is applied as a liquid and hardens to form a gasket the end attached immediately after the can is filled traps gasses inside the can to create pressures of about 30 psi or 2 times atmospheric pressure in soda carbon dioxide produces the pressure in non-carbonated drinks like juices nitrogen is added so why is a beverage can pressurized because the internal pressure creates a strong can despite its thin walls squeeze a closed pressurized can it barely gives then squeeze an empty can it flexes easily the can walls are thin only 75 microns thick and they’re flimsy but the internal pressure of a sealed can pushes outwards equally and so it keeps the wall in tension this tension is key the thin wall acts like a chain in compression it has no strength but in tension it’s very strong the internal pressure strengthens the cans that they can be safely stacked a pressurize can’t easily supports the weight of an average human adult it also adds enough strength so the can doesn’t need the corrugations like in this unpressurized steal food camp well initially pressurize to about two atmospheres a can may experience up to four atmospheres of internal pressure in its lifetime due to elevated temperatures and so the can is designed to withstand up to six atmospheres or 90 psi before the dome or the end will buckle why is there a tab on the end of the can it seems a silly question how else would you open it but originally cans didn’t have tabs very early steel cans were called flat tops for pretty obvious reasons you use a special opener to puncture a hole to drink from and a hold of it in the 1960s the pole tab was invented so that no opener was new the tab worked like this you lift up this ring de vente can and pull the tab to create the opening easy enough but now you’ve got this loose tab the cans ask you to please don’t litter but sadly these pull tabs got tossed on the ground with the sharp edges of the tabs cut the bare feet of beachgoers are they harmed wildlife so the beverage can industry responded by inventing the modern stay on tab this little tab involved clever engineering the tab starts as a second class lever this is like a wheelbarrow because the tip of the tab is the fulcrum and the rivet to load the effort is being applied on the end but here’s the genius part the moment the canvas the tab switches to a first class lever which is like a seesaw where the load is now at the tip and the fulcrum is the rivet you can see clearly how the tab when working as a wheelbarrow lifts the rivet in fact part of the reason this clever design works is because the pressure inside the can helps to force the rivet up which in turn depresses the outer edge of the top until it Vince the can and then the tab changes to a seesaw lever looking from the inside of the can you can see how the tamper stow ppens near the rivet if you try to simply force the scored metal section into the can using the tab as a first class lever with the rivet of the fulcrum throughout you’d be fighting the pressure inside the can the tab would be enormous and expensive if you’d like to learn more about the entire lifecycle of the aluminum can watch this animated video by Wrexham that describes can manufacturing and recycling a typical aluminium can today contains about 70 percent recycled material also discoveries how it’s made as some great footage of the manufacturing machinery here are two different stepwise animations of the entire canned farming process and lastly these are too detailed animations of the cup drawing and redrawing processes the aluminum beverage can is so ubiquitous that it’s easy to take for granted but the next time you take a sip from one consider the decades of ingenious design required to create this modern engineering marvel I’m bill Hammack the engineer guy thanks to Wrexham for providing us with aluminum cans in various stages of production and thank you very much to the advanced viewers who’s in detailed and useful responses for this video we read every single comment if you’d like to help out as an advanced viewer check out engineer Kai comm slash preview you can see upcoming projects and behind-the-scenes footage for example you can see early drafts of this beverage can video and you can sign up to become an advanced viewer thanks again .