Layered Honeycomb Extrusion Die for Uniform Slot Geometry
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Solution Overview
Problem
Extrusion dies used in forming ceramic honeycomb bodies face issues with elastic deflection under high extrusion pressures, leading to pin flowering and non-uniform geometries, which affect the quality and isostatic strength of the extruded honeycomb bodies.
Innovation Solution
A multi-piece layered honeycomb extrusion die is constructed by joining a metal plate with a high-yield strength material to a plate made of a high-elastic modulus material, such as ceramic or metal matrix composite, to increase the effective elastic modulus and prevent die deflection, thereby maintaining slot and web thickness uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-material extrusion die is used, then the device complexity is low, but the elastic modulus is insufficient causing pin flowering and non-uniform geometries under high extrusion pressure
Solution Approach 1:
The extrusion die is constructed as a composite structure with a first plate made of metal and a second plate made of high-elastic modulus material (ceramic or metal matrix composite). This composite construction increases the effective elastic modulus of the die to withstand high extrusion pressures without elastic deflection, thereby preventing pin flowering and maintaining slot and web thickness uniformity.
Solution Approach 2:
The extrusion die is divided into multiple segments or plates (first plate and second plate) that are joined together. The first plate contains the pins and slots, while the second plate provides high elastic modulus support. This segmentation allows each component to perform its specific function optimally while collectively solving the elastic deflection problem.
2Manufacturing precision
If the die thickness is increased to prevent elastic deflection, then the elastic modulus effectiveness improves, but the productivity decreases due to reduced feed rates
Solution Approach 1:
By using high-elastic modulus materials (ceramic or metal matrix composite) in the second plate, the die achieves sufficient stiffness to prevent pin flowering without requiring increased die thickness. This maintains smaller feed hole dimensions and allows for higher extrusion feed rates, thus improving productivity while ensuring pin geometry uniformity.
3Manufacturing precision
If a high-elastic modulus material is used for the entire die, then the elastic deflection is prevented, but the ease of manufacture decreases due to difficulty in forming pins and slots
Solution Approach 1:
The die is segmented into a first plate made of metal (easy to form pins and slots) and a second plate made of high-elastic modulus material (maintains slot geometry consistency). This segmentation allows the pins and slots to be formed in the metal first plate using conventional machining, while the ceramic or composite second plate provides the necessary elastic modulus support.
Solution Approach 2:
Different regions of the die have different material properties optimized for their specific functions. The first plate region contains the pins and slots made of metal for ease of manufacturing, while the second plate region provides high elastic modulus support for geometric consistency. Each local region has the quality it needs for its specific purpose.
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 layered die structure reduces elastic deflection, maintains slot and web thickness uniformity, and allows for reduced die thickness and increased feed rates, improving the quality and performance of extruded honeycomb bodies.
Implementation Method 1
The high elastic modulus of the second plate increases the effective elastic modulus of the extrusion die such that the die can withstand high extrusion pressures without experiencing elastic deflection of the die
Implementation Method 2
The layered die structure reduces elastic deflection, maintains slot and web thickness uniformity
Data Source
AI summary
Extrusion dies and methods of manufacturing extrusions dies, the extrusion die including a first plate and a second plate. The first plate has first upstream and downstream surfaces. A first material of the first plate has a first elastic modulus. The first plate includes pins formed between a plurality of slots. The pins and slots define a discharge face for the extrusion die at the first downstream surface of the first plate. The second plate has second upstream and downstream surfaces. The second plate is joined at the second downstream surface to the first upstream surface of the first plate. A second material of the second plate has a second elastic modulus. The second elastic modulus is greater than the first elastic modulus. A plurality of feed holes extend from the second upstream surface of the second plate through the extrusion die into communication with the slots.