Finite element modelling of the manufacturing process for aluminium aerosol cans

The current paper provides an illustration of the application of non-linear finite element analysis to the modelling of the extrusion and forming processes, using the manufacture of a one-piece aluminium aerosol can by the back extrusion process as an example. It also demonstrates how this numerical method can be used to predict the axial buckling of such cans, which is a potential failure mode during manufacture. The various stages of the modelling process are described and finite element predictions are presented. Where possible, these predictions are compared with experimental results. The paper also highlights some of the modelling issues associated with analyses of this type and provides recommendations as to how the correlation between the model and the actual physical problem can be improved.