Honeycomb Body Horizontal Extrusion Cradle Support
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Solution Overview
Problem
Large honeycomb structures formed by horizontal extrusion are prone to deformation and buckling due to load from the cradle, leading to shape accuracy issues and low yield rates, as existing methods require high hardness of the kneaded material, which reduces productivity and shortens die life.
Innovation Solution
A supporting method where the cradle moves horizontally after lifting from a position below the die, with the lowermost end of the supporting surface positioned below the honeycomb body, maintaining a distance of 5 to 15 mm in the vertical direction, and moving at the same speed as extrusion, to reduce the load applied to the honeycomb body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hardness of the kneaded material is increased to prevent buckling, then the resistance to deformation improves, but the productivity decreases and die life shortens
Solution Approach 1:
The cradle is positioned at a predetermined distance (5-15 mm) below the lowermost end of the honeycomb formed body before the extrusion process completes. This preliminary positioning ensures that the supporting surface is ready to receive the extruded body at the optimal moment, preventing deformation without requiring excessive material hardness
Solution Approach 2:
The invention transitions from vertical support (traditional method where cradle supports from below at zero distance) to horizontal support by positioning the cradle at a distance in the vertical dimension. This dimensional change allows the extruded body to maintain its shape during extrusion while being supported horizontally on the moving cradle, reducing the need for high material hardness
2Stability of the object's composition
If the distance between the supporting surface and the honeycomb body is reduced to improve support stability, then the stability improves, but the deformation and buckling increase due to overload
Solution Approach 1:
The cradle moves horizontally at the same speed as the extrusion process, creating a synchronized support system. This equipotential movement ensures that the honeycomb formed body is continuously supported during extrusion without sudden load changes, maintaining both stability and shape accuracy
Solution Approach 2:
By positioning the supporting surface below the honeycomb body in the vertical dimension rather than directly underneath at the same level, the invention creates optimal load distribution. The 5-15 mm vertical distance allows the body to be supported without concentrated overload points, preventing buckling while maintaining stability
3Reliability
If the cradle supports the honeycomb body directly underneath to maximize support effectiveness, then the support effectiveness improves, but the load increases causing buckling
Solution Approach 1:
The cradle is positioned at a predetermined distance (5-15 mm) below the lowermost end of the honeycomb formed body before extrusion completes. This preliminary positioning allows the cradle to be in the optimal support position when the body is extruded, providing effective support with minimized load
Solution Approach 2:
The invention optimizes the vertical distance parameter between the supporting surface and the honeycomb body to 5-15 mm. This parameter change reduces the load force while maintaining support effectiveness, preventing buckling in large-diameter bodies
Data Source
AI summary
There is disclosed a method capable of effectively suppressing deformation when a honeycomb formed body formed by horizontal extrusion is supported by a cradle, and supporting even a large honeycomb formed body so that cell wall buckling hardly occur and a high shape accuracy is kept, wherein the lowermost end of a supporting surface of the cradle is located below the lowermost end of the honeycomb formed body immediately after extruded through the die during the horizontal movement, and a distance in a vertical direction between the lowermost end of the honeycomb formed body immediately after extruded through the die and the lowermost end of the supporting surface of the cradle is from 5 to 15 mm during the horizontal movement when a honeycomb formed body extruded through a die in a horizontal direction by extrusion is supported by a cradle.