A Numerical and Experimental Analysis of the Mechanical Behavior of the Aluminum Beverage Can with Internal Varnish Layers during Axial Load Force Testing

Abstract

This article presents a numerical and experimental investigation into the impact of can wall thickness and the internal varnish layer thickness on the results of an axial load force test. This study also shows the levels of thermal stresses that emerge after the drying of varnish coating, and how they affect the results of the axial load force test. This research involves the development of suitable numerical models and the experimental acquisition of stress–deformation relationships for the both can material, aluminum, and the varnish. The numerical simulation of the axial load force test has been verified through experimental tests, with a resulting difference of 8.9% between the two sets of results. The findings highlight that changes in the can wall thickness have a more pronounced effect on test outcomes compared to variations in the varnish thickness. Specifically, an increase in the can wall thickness from 90 µm to 100 µm results in a substantial 116 N increase in the force required for a can to collapse. Nevertheless, the presence of a 5 µm varnish layer also contributes measurably, increasing the can’s collapse force by 21 N. These results offer valuable practical insights for manufacturers, enabling them to effectively optimize can strength characteristics.