Honeycomb Structure Contouring via Segmented Grinding
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Solution Overview
Problem
Ceramic honeycomb structures used in engine exhaust systems face challenges in efficient manufacturing, particularly in contouring extruded honeycomb bodies to desired shapes and sizes without edge chipping, which results in low throughput and inefficient part production.
Innovation Solution
A method involving a trapezoidal or partial trapezoidal tool path using a grinding wheel for coordinated axial and radial motion to contour honeycomb bodies, allowing for rapid material removal while minimizing edge chipping, by making two passes: the first pass chamfers the edges and the second pass completes the final shape and diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional contouring methods are used on extruded honeycomb bodies, then the desired shape and size can be achieved, but edge chipping occurs and processing time is excessive
Solution Approach 1:
The contouring operation is divided into two distinct passes: a roughing pass that removes the majority of material quickly, and a finishing pass that precisely contours the final shape. This segmentation allows each pass to be optimized for its specific function, achieving both high productivity and edge quality without chipping.
Solution Approach 2:
The roughing pass performs preliminary material removal to bring the honeycomb body close to the final dimensions before the finishing pass. This preliminary action reduces the workload on the finishing pass, enabling it to focus on precise contouring and edge quality without excessive processing time.
2Loss of time
If rapid material removal is performed, then processing time is reduced, but edge chipping increases
Solution Approach 1:
The material removal process is segmented into roughing and finishing passes. The roughing pass handles rapid material removal with appropriate feed rates and depths of cut, while the finishing pass uses lighter cuts to achieve the final contour without causing edge chipping. This segmentation resolves the contradiction between speed and quality.
Solution Approach 2:
Different cutting parameters and tool approaches are applied to different stages of the process. The roughing pass uses parameters optimized for material removal rate, while the finishing pass uses parameters optimized for surface quality and edge integrity. This local differentiation of process quality eliminates edge chipping while maintaining overall efficiency.
3Productivity
If single-pass contouring is used, then device complexity is reduced, but throughput decreases
Solution Approach 1:
The contouring process is segmented into two passes within a single machining operation. The roughing pass and finishing pass are performed sequentially in the same setup, requiring minimal repositioning or tool changes. This segmentation increases throughput compared to single-pass methods while avoiding the complexity of multiple separate operations.
Solution Approach 2:
The two-pass contouring process is performed in continuous sequence without interrupting the machining cycle. The transition from roughing to finishing is seamless, maintaining continuous useful action on the workpiece. This continuity maximizes throughput while the dual-pass approach optimizes both material removal efficiency and final part quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid and efficient machining of honeycomb structures without edge chipping, significantly reducing processing time and improving part generation efficiency, allowing for precise shaping and sizing of ceramic substrates and filters.
Implementation Method 1
A method involving a trapezoidal or partial trapezoidal tool path using a grinding wheel for coordinated axial and radial motion to contour honeycomb bodies
Data Source
AI summary
A method of manufacturing a honeycomb structure includes providing a honeycomb body having a first contour extending between opposing first and second ends and chamfering a corner of the first end in a radial and axial direction toward the first contour to form a second contour. The method further includes removing material in an axial direction toward the second face to form a third contour, chamfering a corner of the third contour in a radial and axial direction toward the second end to form an end contour, and removing material in an axial direction toward the first face to form a fourth contour. Removing material to form the fourth contour substantially removes the second contour and the end contour.