Honeycomb Extrusion Die Inserts for Complex Slot Patterns
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Solution Overview
Problem
Existing honeycomb extrusion dies are limited in producing complex geometries, as methods like wire EDM can only form linear slots, and more complex patterns using plunge EDM are time-consuming and expensive.
Innovation Solution
A method involving die inserts with runners and teeth is used, where the teeth are inserted into slots to block portions, secured by machining and coating, allowing for the creation of complex honeycomb patterns by preventing material flow through specific sections of the slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire EDM is used to form slots in the extrusion die, then linear slots can be formed efficiently, but complex honeycomb patterns with discontinuous slots cannot be produced
Solution Approach 1:
The die insert is divided into a runner portion and multiple separate teeth portions. The teeth are individually separable from the runner, allowing each tooth to be positioned independently to block specific portions of slots. This segmentation enables the creation of complex discontinuous patterns while maintaining the efficiency of the original wire EDM process for forming the basic slot structure.
2Adaptability or versatility
If plunge EDM is used to form complex patterns in the extrusion die, then complex honeycomb patterns can be produced, but the manufacturing process becomes time-consuming and expensive
Solution Approach 1:
The complex pattern-forming teeth are pre-formed on separate die inserts using efficient wire EDM processes. These pre-formed teeth are then inserted into the extrusion die slots, avoiding the need to perform time-consuming plunge EDM operations on the entire die. This preliminary preparation of pattern elements separately enables complex patterns to be produced efficiently.
Solution Approach 2:
Die inserts serve as intermediary components that carry the complex pattern-forming teeth. Instead of directly machining the complex patterns into the main extrusion die using slow plunge EDM, the patterns are transferred via these intermediary die inserts that can be efficiently manufactured separately and then installed in the die.
3Adaptability or versatility
If die inserts with teeth are inserted into slots to block portions, then complex honeycomb patterns can be created, but the device structure becomes more complex
Solution Approach 1:
The die inserts with separable teeth serve multiple functions: they block portions of slots to create complex patterns, can be removed and replaced to change patterns, and maintain the basic slot structure. This multi-functionality allows a single component design to achieve both structural support and pattern formation, reducing overall system complexity despite the added capability.
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 the production of extruded articles with complex honeycomb patterns, including discontinuous sections and varying opening sizes and shapes, improving performance characteristics such as reduced pressure drop and increased ash storage capacity.
Implementation Method 1
the coating comprises plating... the plating comprises nickel plating
Data Source
AI summary
Methods of manufacturing honeycomb-structure-forming extrusion dies having a number of slots for use in producing extruded articles having complex honeycomb patterns and extrusion dies for use in the manufacture of extruded honeycomb bodies. The method includes inserting a die insert having a runner and a number of teeth into a slot of an extrusion die such that each of the teeth blocks at least a portion of the slot of the extrusion die. The method further includes separating the runner from the teeth so that the teeth remain within the slot of the extrusion die.