Honeycomb Die Slit Formation via Comb Electrode and Liquid Grooves
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Solution Overview
Problem
The existing methods for manufacturing honeycomb structure forming dies with cells of different sizes are inefficient, requiring lengthy processes and resulting in poor processing stability and accuracy due to the need for mesh-shaped electrodes and increased machining removal, which complicates the formation of concavo-convex partition walls.
Innovation Solution
The method involves using a comb-like electrode for electro-discharge machining with processing liquid grooves, allowing the liquid to flow through these grooves to form slits, which reduces the width of the processing liquid grooves and improves processing stability and accuracy by circulating the liquid, enabling the formation of honeycomb structures with different cell sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mesh-shaped electrodes are used for electro-discharge machining to form slits in honeycomb structure forming die, then the slits can be formed, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The mesh-shaped electrode is divided into multiple independent rib electrodes arranged in a comb-like configuration. Each rib electrode corresponds to one side of a hexagonal slit, allowing independent positioning and machining. This segmentation simplifies the electrode structure while maintaining the capability to form complex hexagonal slits accurately.
Solution Approach 2:
Processing liquid grooves are formed in advance before the electro-discharge machining of slits. These pre-formed grooves guide the processing liquid flow to the machining locations, ensuring stable machining conditions from the beginning of the slit formation process, which improves both accuracy and efficiency.
2Ease of manufacture
If conventional electro-discharge machining is used without processing liquid grooves, then the process is simpler, but processing stability and accuracy deteriorate due to insufficient liquid flow
Solution Approach 1:
Processing liquid grooves are formed in advance before the electro-discharge machining of slits. These pre-formed grooves guide the processing liquid flow to the machining locations, ensuring stable machining conditions from the beginning of the slit formation process, which improves both accuracy and efficiency.
Solution Approach 2:
Processing liquid grooves act as intermediary channels that mediate between the liquid supply source and the electro-discharge machining zones. These grooves ensure controlled and sufficient delivery of processing liquid to each machining location, maintaining processing stability without complicating the overall system.
3Productivity
If machining removal amount is increased to form slits in honeycomb structure forming die, then the slits can be formed more quickly, but processing accuracy and stability worsen
Solution Approach 1:
Processing liquid grooves act as intermediary channels that mediate between the liquid supply source and the electro-discharge machining zones. These grooves ensure controlled and sufficient delivery of processing liquid to each machining location, maintaining processing stability without complicating the overall system.
Solution Approach 2:
The machining process utilizes controlled electro-discharge parameters including processing liquid flow rate, voltage, and current density. By optimizing these parameters, the process achieves both high productivity through adequate material removal and high precision through controlled discharge conditions, resolving the contradiction between speed and accuracy.
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
This approach significantly reduces manufacturing time and costs, enhances processing stability, and improves the accuracy of slit width and depth, allowing for the efficient production of honeycomb structure forming dies with alternating cell sizes.
Implementation Method 1
performing comb-like electro-discharge machining with a comb-like electrode where a plurality of plate-shaped protrusion electrodes corresponding with the slit width are disposed in positions including the processing liquid grooves
Implementation Method 2
allowing the processing liquid to flow through these grooves to form slits, which reduces the width of the processing liquid grooves and improves processing stability and accuracy by circulating the liquid
Data Source
Figure 1~2A
Figure 2B~3B
Figure 3C~4A
AI summary
There is provided a method for manufacturing a honeycomb structure forming die including a liquid groove forming step for forming linear processing liquid grooves 3 whose width is smaller than that of the slit 5, in positions for forming the slits 5 for forming the partition walls 41 of the honeycomb structure 40 by subjecting the kneaded clay to extrusion in one side end face 7 as a kneaded clay forming face 17 of a plate-shaped die substrate 2. An introduction hole forming step for forming introduction holes 4 for introducing the kneaded clay is performed before or after the liquid groove forming step. Slits 5 communicating with the introduction holes 4 are formed by performing comb-like electro-discharge machining by a comb-like electrode 21 where plate-shaped protrusion electrodes 23 corresponding with the slit 5 width are disposed in positions including the processing liquid grooves 3.