Effect of tooling geometry on the cutting surface of punched aluminium slugs

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Aluminium slugs are semi-finished products, often in the form of metal disks, that are used to produce various supplies like aerosol cans and components for motor vehicles. Ball technologies d'Aluminium Avancées Canada produce slugs by punching metal strips that are cast and rolled in-house. They have been having difficulties with the production of slugs with a large thickness to diameter ratio (t/d). For ratios approaching 1/1, defects are present on the outer diameter of the slugs, making them inappropriate for further processing. In an effort to understand how the tooling parameters influence the occurrence of defects, microstructural characterization of slugs made with 2 different sets of tooling will be done, and simulations of the process will be performed. The models will be calibrated using tensile and shear tests results, and validated with experiments. They will then be used to study the influence of the tooling parameters on the quality of the slugs.