Honeycomb Electrode Manufacturing via Electric Discharge Machining
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Solution Overview
Problem
Conventional methods for manufacturing honeycomb structure dies with fine slits for producing ceramic filters or catalyst carriers face challenges in maintaining electrode integrity during electric discharge machining, leading to shape abnormalities and reduced yield due to thinning of flat plate-like projections, which results in abnormal honeycomb structures with deteriorated performance.
Innovation Solution
A manufacturing method involving a thick plate-like electrode base body with processing electrodes arranged complementary to the die shape, allowing for precise carving of electrode cells with finer partition walls without breaking or deforming, using electric discharge machining to create a honeycomb electrode suitable for forming dies with narrower slits and thinner partition walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the flat plate-like projections of the combtooth-like electrode are thinned to create narrower slits in the die, then the cell density and filter performance are improved, but the projections easily break or fracture during electric discharge machining
Solution Approach 1:
Instead of thinning the electrode projections to create narrow slits (which causes breakage), the patent inverts the approach by using a thick electrode with a combtooth-like structure where the projections remain thick and strong. The narrow slits are achieved not by thinning the projections themselves, but by the spacing and configuration of these robust projections, thereby maintaining both structural integrity and precision.
Solution Approach 2:
The patent employs a thin film or coating layer on the surface of the thick electrode projections to define the precise slit boundaries. This allows the bulk structure to remain thick and strong while the surface layer defines the narrow slit geometry, separating the structural support function from the precision defining function.
2Reliability
If wire electric discharge machining is used to create an electrode with shape complementary to the die, then the electrode does not break during machining, but the processing time increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the electrode base body with a combtooth-like structure that already possesses the complementary shape features needed for the die. This preliminary structuring allows subsequent electric discharge machining to proceed faster and more efficiently, as the electrode is already partially configured rather than requiring complete formation during machining.
Solution Approach 2:
The electrode is segmented into a combtooth-like structure with multiple projections and recesses that correspond to the die features. This segmentation allows the electrode to be machined in a more efficient manner compared to creating a fully complementary shape, reducing processing time while maintaining reliability.
3Manufacturing precision
If the electrode is made with thin portions corresponding to the die slits to achieve narrow slits in the die, then the die can form thin partition walls, but the electrode deforms during electric discharge machining
Solution Approach 1:
The patent inverts the conventional approach by making the electrode projections thick rather than thin. The thin partition walls in the die are achieved through the spacing and configuration of these thick projections, not by making the projections themselves thin. This maintains electrode shape stability during machining while still enabling precision in the final die features.
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 method enables the production of honeycomb electrodes with electrode partition walls as thin as 0.01 mm, maintaining structural integrity and enhancing the performance of the honeycomb structure by allowing for stable and efficient electric discharge machining, reducing processing time by up to 80% compared to wire electric discharge machining.
Implementation Method 1
discharging electricity from the one or more processing electrodes toward the surface of the electrode base body to carve the electrode base body
Data Source
AI summary
By providing a manufacturing method of an electrode for a honeycomb structure forming die including: arranging a plurality of processing electrodes 161 having a shape which is complementary to that of the flow-through cells, at positions corresponding to the plurality of flow-through cells in the one surface 107B of the electrode base body 102B; discharging electricity from the plurality of processing electrodes 161 toward the one surface 107B of the electrode base body 102B to carve the electrode base body 102B, so that a plurality of electrode cells having a shape which is analogous to that of the flow-through cells are formed in the electrode base body 102B; whereby obtaining a honeycomb electrode where a plurality of electrode cells partitioned by electrode partition walls appear on the one surface.