CN1993202A - 金属纤维，其制造及应用领域 - Google Patents

金属纤维，其制造及应用领域 Download PDF

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CN1993202A
CN1993202A CNA2005800266714A CN200580026671A CN1993202A CN 1993202 A CN1993202 A CN 1993202A CN A2005800266714 A CNA2005800266714 A CN A2005800266714A CN 200580026671 A CN200580026671 A CN 200580026671A CN 1993202 A CN1993202 A CN 1993202A
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fiber
cutter
metal derby
aforesaid right
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CN100525996C (zh
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R·布吕科
J·霍格森
T·黑里希
P·希尔特
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Vitesco Technologies Lohmar Verwaltungs GmbH
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Emitec Gesellschaft fuer Emissionstechnologie mbH
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2027—Metallic material
    • B01D39/2041—Metallic material the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P17/00—Metal-working operations, not covered by a single other subclass or another group in this subclass
    • B23P17/04—Metal-working operations, not covered by a single other subclass or another group in this subclass characterised by the nature of the material involved or the kind of product independently of its shape
    • B23P17/06—Making steel wool or the like
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    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/20—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a flow director or deflector
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明涉及一种借助于切削加工方法通过采用至少一把旋转刀具(3)制造金属纤维(1)的方法。此外还涉及一种包括这种纤维的过滤材料及其制造方法、一种由此形成的颗粒过滤器以及相应地配备的机动车辆。

Description

金属纤维，其制造及应用领域
技术领域
本发明涉及一种用来制造金属纤维的方法。还涉及一种用来实施金属纤维制造方法的装置。此外本发明涉及一种纤维，纤维材料、颗粒过滤器以及一种机动车辆。
背景技术
在汽车内燃机排气系统中采用大量不同的材料，它们经受特别高的温度、腐蚀性气体以及相当大的振动。尽管存在这种恶劣的环境条件这些材料必须在尽可能长的时间内保持其功能。功能主要取决于利用所述材料构成的废气处理装置的类型。可能的废气处理装置有催化转化器、吸附器、颗粒过滤器、混合器、隔热垫、密封件等等。所述材料通常必须是耐高温和耐腐蚀的。为此除了陶瓷材料外金属部件也是特别合适的。
在上述废气处理装置中目前也采用金属纤维。这里金属纤维特别是作为绝热材料和过滤材料越来越强烈地成为兴趣的重点。因为主要是用于汽车制造的构件和材料，以高的生产率实现经济地制造这种金属纤维，是特别令人感兴趣的。由于目前设计成具有非常敏感的电子装置、传感器等的汽车内燃机排气系统的灵敏度和对干扰的敏感度，纤维材料具有长的使用寿命和尽可能高的结构强度是特别是重要的。只有这样才能防止，在运行期间金属纤维部件由于高温和压力差而脱落，所述脱落的部件有时可能被废气流带走，并可能出现在设置在下游的废气处理装置上。
发明内容
本发明的目的是，推荐一种适合于此的方法。这种方法它特别应该适合于满足用于汽车制造中的废气处理装置的批量生产的需要。同时应产生尽可能均匀地成形的纤维。此外应该给出一种用于制造金属纤维的、结构简单的装置，以及用来改善汽车内燃机废气处理的构件和部件。
这通过具有权利要求1中所述步骤的、用于制造金属纤维的方法来实现。本方法其它有利的实施形式在权利要求1的从属权利要求中说明。此外本发明目的还利用包括一具有装置独立权利要求特征的、具有用来固定至少一个金属块的工件接纳部和一刀具的装置来实现。在这种情况下，应该指出，在权利要求中分别列出的特征可以用任意技术上合理的方式相互组合，并形成本发明的其它方案。同样说明书的内容可以用来详细说明权利要求。
按本发明的用于制造金属纤维的方法至少包括以下步骤：
a)准备好至少一个金属块，
b)借助于切削加工方法通过采用至少一把旋转刀具切下纤维。
纤维特别是指细的，薄的细长结构(Gebilde)。因此纤维就是直径优选明显小于长度的结构，特别是长度/直径比至少为10，优选为100或1000。
纤维由金属组成，其中材料基本上相当于所用的金属块。这种金属最好是至少具有铝和铬成分之一的铁材料，最好甚至具有这两种成分。金属材料有利地是可锻的和耐高温的。所列的合金成分用来对于包含在汽车内燃机废气内的有害物质提供高的抗腐蚀性。
这里纤维制造通过对金属块进行切削加工来实现。其中旋转的刀具以确定的切削刃作用到金属块或其表面中，并从实心材料(Vollmaterial)上切下纤维。刀具和金属块之间所需要的(主)相对运动或的(主)相对运动由刀具完成。刀具绕其自身的轴线旋转。这个刀具自身的旋转运动叠加一附加的金属块和刀具之间的相对平移(辅助)运动，即所谓的进给。这里工件和刀具相互以可预先规定的(大多是恒定的)速度运动，从而刀具的切削刃的规定的切入深度切入金属体。用这种方式可制造出均匀的纤维。
按照本方法一种改进方案，纤维的切削借助于端铣刀进行。这里铣削特别是指具有一通常为多齿的、用来形成任意工件表面的刀具的圆形切削运动的切削加工方法。切削运动垂直或倾斜于刀具的旋转轴线分布。在铣削方法的分类上通常例如按照所产生的表面、刀具形状(轮廓)和/或运动规律分为平面铣削、圆周铣削、滚铣、成形铣削和仿形铣削。
如果由刀具端侧利用所谓的副切削刃产生工件表面，则称为端铣。相应地通过在铣刀外周上的切削刃产生表面的铣削方法称为圆周铣。根据刀具旋转和进给方向的不同又进一步分为逆铣和顺铣。在逆铣时进给运动和切削运动方向相反，而在顺铣时这两种运动朝同一个方向。对于这里特别优选的端铣或端面平面铣削，接合尺寸(基本上相当于纤维长度)明显大于切削深度(基本上相当于纤维高度)，工件表面通过副切削刃—即设置在铣刀端侧上的切削刃部分产生。端铣刀优选以每转10至100μm[微米]范围内的进给量工作。
利用这里所推荐的铣削方法可以在特别短的时间内产生非常大数量的均匀的纤维。其中这个(加工)过程通常一直重复到金属块最终耗尽为止。原则上还应该指出，当然也可以同时采用多把铣刀铣削所述金属块，附加地可以采用冷却剂和/或润滑剂，和/或同时进行其它加工过程(例如铣削过的表面的精磨等)。
按照本方法的一种改进方案，切下厚度在10μm至100μm[微米]范围内的纤维。厚度最好在20μm至30μm范围内。纤维希望的厚度以及希望的长度和高度的调整值通过相应地选择旋转的刀具的转速和进给量来调整。其中同时也应该考虑参与接合作用的切削刃的几何形状。
此外建议，切削具有长度在1mm至50mm[毫米]，尤其是在15mm至25mm范围内的纤维。
切下高度在10μm至100μm[微米]范围内的纤维，则特别有利。这里优选的范围也是20μm至30μm。
这里所给出的尺寸特别是为用作废气处理装置的部件的纤维选择的。因此纤维具有必要的横截面，以承受持久的热负荷和动态负荷。此外，所述纤维保证例如主要用来与废气紧密接触的比表面积。此外应该考虑，它们由此还提供合适的交叉点/结点(Knote)的可能性，例如由多根纤维的连接所产生的交叉点。这里所出现的利用接合技术和/或材料技术的连接具有足够的强度。
按照本方法一种有利的改进方案，所述至少一把刀具以可预先规定的转速旋转，并以可预先规定的进给量相对于所述至少一个金属块运动，其中这样来选择转速和进给量，即，使纤维在其长度的至少50％上具有一致的厚度。从而确保，纤维至少在其长度的大部分上基本上做得相同，从而在纤维以后合并成织物、针织品等时在相邻纤维相互之间提供足够大的接触区。纤维有利地在其长度的至少80％上，最好甚至在90％或95％上，具有统一的厚度。为了说明清楚，应该指出，“统一的厚度”这种表述还理解为也包含一定的制造误差。应该包含多大的制造误差，主要取决于制造方法；这里对于铣削制造误差允许在平均值左右+/-20％的范围内波动。
此外建议，所述至少一个金属块具有基本上对应于刀具轮廓的加工正面(Bearbeitungsfront)，这特别是指，金属块的加工正面—即旋转刀具作用到其中的正面基本上“紧贴”在刀具轮廓上。这意味着，例如，加工正面设计成具有基本上对应于刀具半径的半径。由此可以保证，在整个加工过程中—即从刀具切入工件到从工件中移出，切削参数不变。此外，如果设置相应的、即具有和刀具相同的半径的金属块背面，则是有利的。因此加工正面有利地设计成凹的，而背面设计成凸的。这里旋转刀具位于加工正面中间，并设有进给量。
此外建议，在顺序相邻的平面内进行切削加工，其中在相邻接平面内所述至少一把旋转的刀具进入所述至少一个金属块内的接合作用错开地进行。这是基于这样的思想，即在加工金属块期间，在切削刃口附近的表面内产生不平度，例如沟槽、刻痕、凸起等。现在这里建议，在切下金属块下一个表层的下一个加工步骤中实现这样的错位，即，现在所形成的不平度不是布置在相对于上面平面的不平度垂直的平面内。这里错位量最好在纤维厚度一半的范围内。因此根据进给量和转速以及切削刃数量的设定不同，在一些情况下在纤维内形成预定断裂部位(Sollbruchstelle)。这使得可以用简单的方式通过附加的加工步骤进一步减小纤维横截面。此外例如可以产生特殊的、例如近似于圆的、椭圆的或多边形的横截面。
此外推荐一种用来制造过滤材料的方法，其中首先按上述方法制造纤维，接着利用接合技术(fügetechnisch)使所述纤维相互连接，这时形成一透气层。为了形成利用接合技术的连接，可以使用辅助材料，但是也可能通过压力和/或温度的作用使纤维相互形成材料锁合连接(例如焊接，烧结等等)。其中纤维可以相互按定向地或杂乱地定位。由此最终形成一透气层，其中流体或气体可以流过利用纤维构成的层的空腔。层最好具有一在小于4mm[毫米]，特别是小于2mm范围内的层厚。通过纤维相互间的布置，提供平均约为40至90％的层的多孔度。所述层优选用来捕捉发动机废气流中携带的炭黑颗粒或其它固体物质。为此过滤材料可以包括其它材料，例如涂层、金属泡沫、陶瓷泡沫、支承结构、催化剂等。
按照本发明的另一个方面，建议一种包括一用来固定至少一个金属块的工件接纳部和至少一把旋转的刀具的装置，为了实现上述按本发明的方法可以使所述刀具与至少一个金属块接合作用，其中所述至少一个旋转刀具包括一多刃铣刀，特别是端铣刀。铣刀特别是指具有多个切削刃的或其切削刃多次开槽或中断的用于切削的刀具。铣刀的切削刃最好均匀地相互隔开并设置在外周和/或端侧上。在这种情况下优选采用升降台/控制台(Konsole)结构形式的万能数控铣床。高度可调的、带有工件接纳部的工作台还附加地进行二维的水平运动(例如用来实现进给运动)。第三移动轴(例如用来调整切削深度)位于用于旋转的、多刃端铣刀的驱动装置的主轴箱(Spindelstock)内。
除此以外，还可以采用十字台设计，这里用这个名称称呼这样的结构，其中在台上实现两个垂直的进给运动，一个运动配设给携带刀具的组件(大多是支架)，另一个运动配设给支承工件的组件(大多是台架)。这里存在不同的实现所述运动轴的可能性。其中水平运动优选由台架或工件接纳部实现，而垂直运动通过旋转的刀具实现。
最好采用带刀片座的镶齿端铣刀(Messerkopfstirnfrser)作为端铣刀，其中例如采用夹紧的硬质合金可转位刀片作为切削刃。这种镶齿端铣刀有上达250mm[毫米]的直径。目前优选的切削速度(vC)在1至20m/min[米每分钟]的范围内，每齿进给量(fZ)在0.02至0.1mm范围内，切削深度(ae)在0.02mm至0.1mm[毫米]范围内。
用本发明的方法或本发明的装置制造的纤维的特征为高的形状精度，因此构成可以耐久地用在汽车内燃机排气系统中的废气处理部件的基础。
例如过滤材料可以至少部分由这种纤维构成。这里废气流过过滤材料，从而包含在废气内的颗粒或固体物质沉积在纤维上或设置在纤维上的涂层上。通过采用还原剂或用其它方式，例如通过提高温度，现在可以连续地在规定时刻断续地再生过滤材料，这时固体物质至少部分转化成气体成分。
用这种过滤材料例如可以为各种不同的发动机(柴油机、汽油发动机等)的排气系统提供颗粒过滤器，所述排气系统的特征是长的使用寿命和高的效率。这里颗粒过滤器可以只由过滤材料构成，但是过滤材料最好仅是颗粒过滤器的一部分。其中特别优选用至少部分形成表面结构的板层形成通道，其中过滤材料至少部分限定这种通道壁。薄板设计成使流过的废气和包含在其中的颗粒向过滤材料转向。由此使流过过滤材料的颗粒(轨迹)留在过滤材料内。
特别有利的是，至少一个上述类型的具有过滤材料和/或颗粒过滤器的废气处理部件内置在一车辆内，车辆特别是指乘用车、载重汽车、摩托艇、机动飞机等。
附图说明
下面借助于附图详细说明本发明。其中除技术背景以外附图还示出本发明特别优选的实施形式，但是本发明并不局限于此。附图表示：
图1示意性示出借助旋转刀具对金属块进行的加工；
图2以透视图示意性示出端铣刀；
图3示出加工后金属块的局部视图；
图4示出带有具有纤维的颗粒过滤器的车辆；以及
图5示出图4中的颗粒过滤器的细节。
具体实施方式
图1以侧视图示意性示出一端铣刀11，该端铣刀可绕其轴线33沿旋转方向17旋转。端铣刀11具有一带多个切削刃12的基体28。在所示的实施形式中，端铣刀11设计成具有4个均匀分布地设置外周上的切削刃12，但是也可以具有6个、8个、12个或更多切削刃。端铣刀11以进给方向18相对于金属块2运动，其中该相对运动通常由金属块2或工件台产生。在实施本方法时使切削刃12与金属块2进入接合作用，其中以高度6和厚度4分离出纤维1。
图2中以透视图示意性示出用来制造纤维1的装置以及方法。金属块2用工件接纳部10固定。为了保证旋转刀具3均匀地切入金属块2，所述金属块具有基本上对应于刀具3的轮廓8的加工正面7。这里刀具3的轮廓8是指首先与金属块2进入接合(的部分)。在所示实施方案中旋转刀具3具有大于金属块2宽度30的直径。因此这是端面铣削加工方法。这里按沿规定的加工平面的各层切削金属块2，这时产生纤维1。在图2的左下方详细示出了纤维1。其中特别示出了纤维1的高度6、厚度4和长度5。
图3以横剖视图示出金属块2的两个细部，其中特别示出在用旋转刀具3加工后金属块2的表面状况。从金属块2上切下纤维1在不同平面9内进行，所述平面相互最好具有保持不变的距离。通过用旋转刀具3的切削刃12进行加工产生不光滑的表面21，其中特别是形成所示的凸起22。
在用“A”表示的制造方案中，相邻平面9的凸起22位于基本上垂直的直线或平面内。这意味着，所有纤维1都制造成具有这样的横截面29，该横截面在整个厚度4上具有相同的高度6。
与此不同，在用“B”表示的方法方案中，在相邻平面9上实现一个错位19。这里形成具有变化的高度6的纤维1，其中如果错位19大致相当于纤维1厚度的一半，则最小的高度6在纤维1厚度4的中部形成。
图5示意性示出这种纤维1在汽车领域的优选应用。这里纤维1相互连接成一个层20，并设有涂层。所述层20布置在部分形成表面结构的金属薄板23之间，所述金属薄板形成多个相互平行设置的通道24。此外金属薄板23具有使废气朝过滤材料13或纤维层20转向的微结构27。这里废气首先沿流动方向32流入通道24，并由于微结构27转向，从而使包含在其中的炭黑25沉积在层20内。炭黑20可连续地再生。
图4中所示的细部示出颗粒过滤器14，它安装在机动车辆15的汽车内燃机26的排气系统31内(见图4)。在颗粒过滤器14之前，即在内燃机26和颗粒过滤器14之间，设置另一废气处理部件16，例如一氧化催化器，该催化器使包含在废气中的氮氧化物转化，以使颗粒过滤器14内的炭黑能连续地再生。
附图标记表
1纤维                2金属块
3刀具                4厚度
5长度                6高度
7加工正面            8轮廓
9平面                10工件接纳部
11端铣刀             12切削刃
13过滤材料           14颗粒过滤器
15车辆               16废气处理部件
17旋转方向           18进给方向
19错位               20层
21表面               22凸起
23金属薄板           24通道
25炭黑               26内燃机
27微结构             28基体
29横截面             30宽度
31排气系统           32流动方向
33轴线

Claims (14)

1.用来制造金属纤维(1)的方法，至少包括以下步骤：
a)提供至少一个金属块(2)；
b)借助于切削加工方法通过采用至少一把旋转刀具(3)切下纤维(1)。
2.按权利要求1的方法，其特征在于，步骤(b)借助于端铣刀进行。
3.按权利要求1或2的方法，其特征在于，切下厚度(4)在10μm至100μm[微米]范围内的纤维(1)。
4.按上述权利要求之任一项的方法，其特征在于，切下长度(5)在1mm至50mm[毫米]范围内的纤维(1)。
5.按上述权利要求之任一项的方法，其特征在于，切下高度(6)在10μm至100μm[微米]范围内的纤维(1)。
6.按上述权利要求之任一项的方法，其特征在于，所述至少一把刀具(3)以可预先规定的转速旋转，并以可预先规定的进给量相对于所述至少一个金属块(2)运动，其中这样来选择所述转速和进给量，即，使纤维(1)至少在其长度(5)的50％上具有一致的厚度(4)。
7.按上述权利要求之任一项的方法，其特征在于，所述至少一个金属块(2)具有一基本上对应于刀具(3)的轮廓(8)的加工正面(7)。
8.按上述权利要求之任一项的方法，其特征在于，切削加工在相邻接的平面(9)内顺序进行，其中所述至少一把旋转刀具(3)在相邻接的平面(9)内错开地接合作用到所述至少一个金属块(2)内。
9.用来制造过滤材料(13)的方法，其特征在于，首先按上述权利要求之任一项制造纤维(1)，接着利用接合技术使所述纤维相互连接，这时形成透气的层(20)。
10.装置，包括一用来固定至少一个金属块(2)的工件接纳部(10)和至少一把旋转的刀具(3)，为了实施按上述权利要求之任一项的方法，可使所述刀具与所述至少一个金属块(2)接合作用，所述至少一把旋转刀具(3)包括一多切削刃的铣刀，特别是端铣刀(4)。
11.用按权利要求1至8之任一项的方法或用按权利要求10的装置制造的纤维(1)。
12.至少部分包括按权利要求11的或按权利要求9制造的纤维(1)的过滤材料(13)。
13.包括按权利要求12的过滤材料(13)的颗粒过滤器(14)。
14.至少具有至少一个带按权利要求12的过滤材料(13)的废气处理部件(16)或至少一个按权利要求13的颗粒过滤器(14)的机动车辆。
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US7510589B2 (en) 2009-03-31
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JP4944028B2 (ja) 2012-05-30
EP1773537B1 (de) 2012-06-13
US20070151218A1 (en) 2007-07-05
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