Honeycomb Electrode Manufacturing via Segmented EDM
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Solution Overview
Problem
Existing methods for manufacturing honeycomb structures with high cell density and thin partition walls face challenges such as electrode breakage and deformation during electric discharge machining, leading to abnormal cell shapes and reduced yield in ceramic products.
Innovation Solution
A manufacturing method for an electrode that involves processing a thick plate-like electrode base body with holes to form shapes corresponding to porous partition walls, allowing for the creation of a honeycomb electrode with complementary shapes to the die, which reduces the risk of breakage and deformation during machining, and enables the production of thinner slits and partition walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrode is made with thin ribs to match narrow slits for thin partition walls, then the honeycomb structure can achieve higher cell density and thinner partition walls, but the electrode easily breaks during electric discharge machining
Solution Approach 1:
The electrode is divided into a thick plate-like base body and multiple thin processing electrodes inserted into holes. The base body provides structural strength while the inserted processing electrodes perform the machining function, separating the structural support function from the machining function.
Solution Approach 2:
Processing electrodes are inserted into holes of the thick plate-like electrode base body to serve as intermediaries that discharge electricity toward the side surfaces of the holes. This allows the thick base body to provide strength while the processing electrodes enable precise machining of narrow slits.
2Strength
If the electrode shape is made complementary to the die shape to prevent breakage, then the electrode strength improves, but electrode portions corresponding to slits become thin and deformation occurs during machining
Solution Approach 1:
The electrode structure is segmented into a thick plate-like base body that provides strength and multiple processing electrodes inserted into holes that perform machining. This segmentation allows the base body to prevent deformation while processing electrodes maintain dimensional accuracy.
Solution Approach 2:
The invention transitions from a two-dimensional thin rib electrode to a three-dimensional thick plate-like electrode with holes. This dimensional change allows the electrode to have sufficient thickness for strength while creating narrow slits through the holes where processing electrodes are inserted.
3Ease of manufacture
If wire electric discharge machining is used to prepare the electrode with complementary shape, then the electrode can be manufactured, but much time is required for processing
Solution Approach 1:
The thick plate-like electrode base body is prepared in advance with holes formed at positions corresponding to flow-through cells. This preliminary preparation of the base body structure enables faster subsequent processing compared to creating the entire electrode shape through slow wire electric discharge machining.
Solution Approach 2:
The electrode manufacturing process is segmented into preparing the thick plate-like base body with holes and then inserting processing electrodes. This segmentation allows parallel processing and reduces the total manufacturing time compared to traditional wire electric discharge machining of the entire electrode.
4Manufacturing precision
If the number of cells per square inch is increased to 400-900, then the honeycomb structure achieves higher filtration efficiency, but the slits become narrower and require thinner electrodes that are more prone to breakage
Solution Approach 1:
The invention transitions from thin rib electrodes to a thick plate-like electrode structure with holes. This dimensional change enables the electrode to accommodate a higher number of cells per square inch (400-900) by providing sufficient material thickness to prevent breakage while allowing narrow slits for high cell density.
Solution Approach 2:
The electrode is segmented into a thick plate-like base body providing structural reliability and processing electrodes inserted into holes that create the narrow slits for high cell density. This segmentation allows achieving 400-900 cells per square inch while maintaining electrode reliability.
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 allows for the production of honeycomb structures with thinner partition walls and higher strength electrodes, reducing processing time by up to 80% compared to traditional wire electric discharge machining, while maintaining the integrity of the electrode and improving the yield of ceramic products.
Implementation Method 1
inserting processing electrodes into the plurality of holes, respectively, and discharging electricity from the insides of the holes toward side surfaces of the holes of the electrode base body to process the side surfaces of the holes of the electrode base body into shapes corresponding to the porous partition walls
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A~3B
AI summary
[Problems] To provide means which enables obtaining in a short time, by electric discharge machining, an electrode that does not break or is not deformed during the electric discharge machining, and which enables obtaining a die including thin or narrow slits for obtaining a honeycomb structure including thin partition walls. [Solution] By providing a manufacturing method of an electrode for a honeycomb structure forming die including: preparing a thick plate-like electrode base body made of an electricity discharging material and having two surfaces; making a plurality of holes in the electrode base body at positions corresponding to flow-through cells; inserting processing electrodes into the holes, and discharging electricity from the insides of the holes toward side surfaces of the holes of the electrode base body to process the side surfaces of the holes of the electrode base body into shapes corresponding to the porous partition walls; whereby obtaining an electrode where a plurality of electrode cells partitioned by electrode partition walls appear on at least one of the surfaces thereof.