Honeycomb Die Back Plate With Enlarging Through Holes
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Solution Overview
Problem
The existing dies for forming honeycomb structures face challenges in reducing the resistance of the forming material during extrusion and the outward flow resistance on the surface of the die, leading to fluctuations in flow properties and wear-related issues that affect the forming properties of the outer wall.
Innovation Solution
A die with a plate-like main body and a detachable back plate having through holes with an enlarging shape and a diamond-like carbon film, where the opening portions of the through holes are designed to reduce resistance by enlarging toward the die main body surface, with specific surface roughness and depth configurations to minimize flow resistance and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the die has conventional back holes with uniform cross-section, then the structure is simple and easy to manufacture, but the resistance of the forming material during extrusion is high
Solution Approach 1:
The through holes are designed with curved surfaces instead of straight cylindrical shapes. The inner peripheral surface forms a smooth curved transition from the introducing portion to the forming portion, eliminating sharp corners and reducing flow resistance of the forming material during extrusion.
Solution Approach 2:
The through holes are pre-formed with optimized curved geometry in the die structure before the extrusion process begins. This preliminary design of the flow path ensures smooth material flow and reduced resistance during the actual extrusion operation.
2Device complexity
If the die surface has conventional flat or worn configuration, then the structure is simple, but the outward flow resistance on the die surface is high causing flow property fluctuations
Solution Approach 1:
The introducing portion surface is given a specific convex-concave configuration with localized peaks and valleys. This local surface modification in the material introduction region controls the outward flow of forming material, reducing flow resistance and preventing flow property fluctuations without complicating the entire die structure.
3Stability of the object's composition
If the die surface is worn, then the die structure remains unchanged, but the forming properties of the outer wall deteriorate due to flow property fluctuations
Solution Approach 1:
The convex-concave configuration is specifically designed in the introducing portion to compensate for wear effects. The localized surface features control material flow in the critical introduction region, maintaining outer wall forming properties even as the die undergoes general wear over time.
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
The solution effectively decreases the resistance of the forming material during extrusion and outward flow, reducing the generation of defects like 'hangnails' and pores in the honeycomb structure, while enhancing wear resistance and maintaining the die's performance over time.
Implementation Method 1
the back plate has a diamond-like carbon film (a DLC film) on the surface thereof
Implementation Method 2
the opening portions of the through holes formed in the back plate in the one surface of the die main body have such an enlarging shape as to enlarge toward the one surface of the die main body
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A die 1 for forming the honeycomb structure includes: a plate-like die main body 4 including an introducing portion 3 provided on the side of one surface thereof and having a plurality of back holes 7 and a forming portion 2 provided on the side of the other surface thereof and having slits 6; and a back plate 5 detachably attached to the surface of the introducing portion 3 and having a plurality of through holes 9 connected to the back holes 7 of the introducing portion 3. Through hole opening portions 12 of the through holes 9 formed in the back plate 5 in the one surface of the die main body have such an enlarging shape as to enlarge toward the one surface of the die main body. The die 1 for forming the honeycomb structure can decrease the resistance of a forming material during extrusion.