Ironingsmoothing

Ironingsmoothing is a term used in metal forming to describe an integrated process that combines ironing with a smoothing operation to produce a high-quality, uniform wall thickness and smooth surface finish in cylindrical metal parts. The term is not universally standardized and may appear in industry manuals, research papers, and practice as a descriptive label rather than a formal process name.

In practice, ironing reduces the diameter and wall thickness of a workpiece by performing controlled plastic deformation in an ironing die, while smoothing is achieved through secondary finishing steps such as polishing, burnishing, or polishing rollers within or after the ironing sequence. Some systems integrate these stages in a single machine or tooling set to minimize handling and improve symmetry.

Common applications include hollow cylindrical products such as beverage cans, seamless tubes, and precision sleeves made from ductile metals like aluminum, copper alloys, and low-carbon steels. The feasibility depends on ductility, work hardening characteristics, and tool wear considerations.

Advantages of ironingsmoothing include improved wall uniformity, reduced porosity at the inner surface, and a smoother exterior surface, enabling tighter tolerances and better cosmetic appearance. Limitations include equipment complexity, higher tooling costs, and constraints on material type and thickness.

See also: ironing (metalworking), tube drawing, surface finishing, burnishing.