Extrusion Die Thickness Ratios for Porous Ceramic Molding
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Solution Overview
Problem
Conventional dies for extrusion-molding of porous ceramic members face challenges in maintaining appropriate molding pressure, preventing defects, and extending die durability, leading to issues with dimensional accuracy and product quality.
Innovation Solution
A die for extrusion-molding with specific thickness ratios for the molding groove, material supplying, and die holding parts, along with a plate-shaped molding groove part and material supplying part configuration, to optimize molding pressure and prevent defects, ensuring efficient production of ceramic molded bodies with high dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional die structure is used for extrusion-molding, then production can proceed with standard equipment, but molding pressure cannot be maintained appropriately leading to defects and reduced dimensional accuracy
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness dimensions of critical die components. Specifically, the molding groove part thickness is set to 3-6mm, material supplying part thickness to 5-10mm, and die holding part thickness to 3.5-8.5mm. These parameter optimizations enable appropriate molding pressure maintenance while achieving high dimensional accuracy in the extruded ceramic members.
Solution Approach 2:
The die structure is segmented into three distinct functional parts: the molding groove part, the material supplying part, and the die holding part. Each segment is independently optimized for its specific function - the molding groove part for shape formation, the material supplying part for material delivery, and the die holding part for structural support. This segmentation allows each component to be optimized for its specific role in maintaining molding pressure and dimensional accuracy.
2Ease of manufacture
If conventional die configuration is used, then manufacturing process is simpler, but defects such as cracks and deformation occur frequently
Solution Approach 1:
The patent optimizes the thickness parameters of each die component to prevent defects. The molding groove part thickness of 3-6mm prevents cracking during extrusion, while the material supplying part thickness of 5-10mm ensures uniform material flow. The die holding part thickness of 3.5-8.5mm provides sufficient structural support to prevent deformation. These parameter changes maintain relative manufacturing simplicity while dramatically reducing defects.
3Productivity
If standard die design is used, then initial production setup is faster, but die durability and operational lifespan are reduced
Solution Approach 1:
The patent extends die operational lifespan through optimized thickness parameters. The die holding part with thickness of 3.5-8.5mm provides enhanced structural durability, while the material supplying part with thickness of 5-10mm resists wear from continuous material flow. These parameter optimizations allow the die to maintain high productivity while significantly extending its operational lifespan before requiring replacement or refurbishment.
Data Source
AI summary
A die for extrusion-molding in accordance with the present invention comprises: a molding groove part, a material supplying part, and an outer frame for fixing a die main body comprising the molding groove part and the material supplying part to the front end of an extrusion-molding apparatus, whereinthe die main body has a form in which the plate-shaped molding groove part smaller than the material supplying part is provided at almost the middle of the plate-shaped material supplying part such that it protrudes from the material supplying part,the outer frame comprises: a die holding part which is provided such that it covers the material supplying part around the molding groove part; and a peripheral part which is provided near the die holding part, andsupposing that the thickness of the molding groove part is X, the thickness of the material supplying part is Y, and the thickness of the die holding part of the outer frame is Z, these X, Y and Z are allowed to satisfy the inequalities (1) about 3≦X≦about 6, (2) about 5≦Y≦about 10, (3) about 3.5≦Z≦about 8.5, (4) about 0.8<Y/X<about 2.5, and (5) about 1<Z/X<about 2.