JP2000326318A - Die for molding honeycomb structural body and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a die for honeycomb structural body molding die, with which a honeycomb structural body can be molded without development of troubles such as strains or the like, by a wire electrical discharge machining. SOLUTION: This die is for molding a honeycomb structural body having feeding holes 131, through which a material is fed, and slit grooves 15, which communicate with the feeding holes 131 so as to mold the material into a honeycomb shape. On a first die material 11, a large number of independent stripes of through primary-grooves 115 are formed by a wire electrical discharge machining. After a second die material 12 is bonded to the top surface of the first die material 11, similarly, secondary grooves 125 are formed. As a result, in the first die material 11, the secondary grooves 125 form a honeycomb-like slit groove 15 together with the primary grooves 115. After a holed die material 13 is bonded on the under surface of the first die material 11, the second die material 12 is removed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb structure forming die for manufacturing a honeycomb structure formed body by wire electric discharge machining and a method for manufacturing the same.

[0002]

2. Description of the Related Art For example, a ceramic honeycomb structure mainly composed of cordierite or the like is manufactured by extruding a material using a molding die. In this honeycomb structure, a large number of cells are configured by providing partition walls in a lattice shape, and the cell shape has various shapes such as a quadrangle and a hexagon.

[0003] For example, to manufacture a honeycomb structure having hexagonal cells, a mold having hexagonal lattice-like slit grooves is used. Specifically, as shown in FIG. 2, a honeycomb structure forming die having a supply hole 131 for material supply and a slit groove 15 provided in a hexagonal lattice shape in communication with the supply hole 131 is used. .

[0004] As a method of manufacturing the honeycomb structure forming die as described above, there is a manufacturing method using wire electric discharge machining disclosed in Japanese Patent Application Laid-Open No. 2-52703. A method for manufacturing the above-mentioned conventional honeycomb structure forming die 9 will be described with reference to FIGS. In FIG. 16, (A-1) to (D-1) are perspective views in which the upper surfaces of the primary processed body to the tertiary processed body and the honeycomb structure forming die 9 are upward, and FIG. 2) to (D-2) are perspective views with the lower surface facing upward.

First, a plurality of independent primary grooves 915 penetrating from each other are formed in the first mold material 91 by wire electric discharge machining to obtain a primary processed body 901 (FIG. 16A-A).
1), (A-2)). Next, the second mold material 92 is joined to the upper surface of the primary processing body 901 to obtain a secondary processing body 902 (FIGS. 16 (B-1) and (B-2)).

Next, a plurality of independent secondary grooves 925 are formed in the secondary processing body 902 by wire electric discharge machining to obtain a tertiary processing body 903 (FIG. 16C-1). )). At this time, the first mold material 9
In 1, the honeycomb-shaped slit groove 95 is formed by the secondary groove 925 communicating with the primary groove 915 (FIG. 16C-2).

Next, the die 9 for forming a honeycomb structure is obtained by joining the die material 93 having the supply holes 931 to the lower surface of the second die material 92 (FIG. 16D-). 1), (D-2)). At this time, as shown in FIG. 17B, the supply holes 931 are joined so as to be arranged at the intersections of the slit grooves 95.

In this way, the honeycomb structure forming die 9 is manufactured by using the wire electric discharge machining. In the above manufacturing method, since wire electric discharge machining is used, a honeycomb structure forming die can be manufactured easily and with high production efficiency in an arbitrary honeycomb-shaped slit groove.

[0009]

However, the above-described conventional method for manufacturing the honeycomb structure forming die 9 has the following problems. That is, since the honeycomb structure forming die 9 has a three-layer structure with the second die material 92 interposed between the first die material 91 and the perforated die material 93, the first die material 91 has a three-layer structure.
The slit groove 95 formed in the mold material 91 is not directly connected to the supply hole 931 (FIG. 17A).

That is, as shown in FIG. 17D, a hexagonal honeycomb slit groove 95 is provided in the first die material 91. That is, one unit of the hexagon is formed by six-sided slit grooves indicated by reference numerals M, N, O, P, Q, and R in FIG.

On the other hand, the second mold material 92 has the structure shown in FIG.
(C), as shown in FIG.
25 is only formed in a zigzag shape. That is, as shown in FIG.
In the portion corresponding to the hexagon formed by the slit grooves M, N, O, P, Q, R, the secondary grooves S, T,
Only U and V are formed.

For this reason, the material supplied to the supply hole 931 is supplied to the secondary grooves S, T, U, V, which are directly supplied to the slit grooves M, N, O, Q. It is not directly supplied to P and R. As a result, the material is not sufficiently supplied to the slit grooves P and R, and the honeycomb structure extruded from the honeycomb structure forming die 9 may have a problem such as distortion.

Further, the material supplied to the secondary groove 925 is molded to some extent here and impairs the fluidity, so that it is difficult to uniformly supply the material to the entire area of the slit groove 95. Therefore, there is a possibility that a defect such as distortion may occur in the obtained honeycomb structure.

The present invention has been made in view of the above-mentioned conventional problems, and a honeycomb structure forming mold capable of forming a honeycomb structure free from defects such as distortion is formed by wire electric discharge machining. It is an object of the present invention to provide a honeycomb structure forming mold which can be manufactured by a method and a method for manufacturing the same.

[0015]

According to the first aspect of the present invention, there is provided a honeycomb structure having a supply hole for supplying a material, and a slit groove communicating with the supply hole for forming the material into a honeycomb shape. In a method of manufacturing a mold, the manufacturing method includes the steps of: forming a plurality of independent one-pieces through a first mold material;
A first step of forming a primary groove by wire electric discharge machining to obtain a primary workpiece, and a second step of joining a second mold material to an upper surface of the primary workpiece to obtain a secondary workpiece. A plurality of penetrating secondary grooves independent of each other are formed in the secondary processing body by wire electric discharge machining. At this time, the secondary grooves communicate with the primary grooves in the first mold material. By forming the honeycomb-shaped slit groove formed by the above,
A third step of obtaining a tertiary processing body, a fourth step of joining a perforated mold material having the supply holes to a lower surface of the first die material to obtain a quaternary processing body, And a fifth step of removing the second die material from the above. 5. A method for manufacturing a die for forming a honeycomb structure, comprising:

It is most remarkable in the present invention that, in the fourth step, a perforated mold material is joined to the lower surface of the first mold material, and in the fifth step, the second workpiece is removed from the fourth work body. It is to remove the mold material. That is, the perforated mold material is directly joined to the lower surface of the first mold material in which the honeycomb-shaped slit grooves are formed (see FIG. 1 (D-
1), (D-2)). Thereafter, the second mold material bonded to the upper surface of the first mold material is removed (see FIG.
1), (E-2)).

Next, the operation and effect of the present invention will be described.
In the above method for manufacturing a honeycomb structure forming mold,
As described above, the perforated mold material is directly joined to the lower surface of the first mold material in which the honeycomb-shaped slit grooves are formed, and then the second mold material is joined to the upper surface of the first mold material.
Remove mold material.

For this reason, the slit groove of the die for forming a honeycomb structure obtained by the above-described manufacturing method is directly connected to the supply hole. Therefore, in forming the honeycomb structure, the material supplied to the supply hole is directly supplied to the slit groove. That is, the material supplied to the supply hole is directly supplied to the slit groove while maintaining fluidity. Therefore, the material is uniformly supplied to the entire area of the slit groove, and there is no possibility that a problem such as distortion of the formed honeycomb structure occurs.

As described above, according to the present invention, a honeycomb structure forming die capable of forming a honeycomb structure free from defects such as distortion can be manufactured by using wire electric discharge machining. A method for manufacturing a mold for forming a structure can be provided.

Next, a honeycomb structure having a supply hole for supplying a material and a slit groove for communicating the material with the supply hole and forming the material into a honeycomb shape according to the present invention. In the method of manufacturing a molding die, the manufacturing method includes forming a plurality of penetrating primary grooves connected to the first die material in a single stroke by wire electric discharge machining.
A first step of obtaining a primary workpiece, and a second step of joining a second mold material to an upper surface of the primary workpiece to obtain a secondary workpiece;
A plurality of penetrating secondary grooves connected in a single stroke are formed in the secondary processing body by wire electric discharge machining, and the secondary grooves are formed in the first mold material by the primary grooves. A third step of obtaining a tertiary processed body by forming the honeycomb-shaped slit groove formed by the communication, and placing a perforated mold material having the supply holes on a lower surface of the first mold material; A method for manufacturing a die for forming a honeycomb structure, comprising: a fourth step of joining to obtain a fourth processed body; and a fifth step of removing the second die material from the fourth processed body. There is.

That is, in the first step and the third step, unlike the first aspect of the invention, the multiple primary grooves and the secondary grooves are formed by being connected in a single stroke without being independent from each other. (See FIGS. 5A-1 and 5C-1). Therefore, there is no need to provide a large number of small-diameter through holes used as a starting point in wire electric discharge machining. Further, it is not necessary to perform a setup operation every time the primary groove or the secondary groove is processed by one. Therefore, it is possible to manufacture the honeycomb structure forming mold with higher production efficiency.

Next, in the fifth step, the second die material can be removed by surface grinding in the fifth step. Thereby, the second mold material can be easily removed. In this case, there is an advantage that the processing time is particularly short and the finished surface is smooth.

Next, in the fifth step, the second mold material can be removed by wire cutting in the fifth step. Also in this case, the second mold material can be easily removed. In this case, there is an advantage that no burr is generated.

Next, as in the fifth aspect of the present invention, the slit groove may be any one of a square, a hexagon, and a circle. That is, one lattice of the honeycomb formed by the slit grooves can be square, hexagonal, or circular.

As a result, it is possible to obtain a honeycomb structure forming die for forming a honeycomb structure having an arbitrary slit groove such as a quadrangular shape and having each shape.
In addition, the method for manufacturing the honeycomb structure forming mold is such that the slit groove is formed by wire electric discharge machining.
Either of the above slit grooves can be easily processed.

Next, as in the sixth aspect of the present invention, the first mold material is joined to the second mold material, and the first mold material and the perforated mold material are joined together. The joining is preferably performed by interposing a joining medium on the joining surface.
This makes it possible to easily and reliably perform the joining between the first mold material and the second mold material and the joining between the first mold material and the perforated mold material.

Next, as in the invention as set forth in claim 7, the joining medium is previously joined to both surfaces of the first mold material, and the primary groove is connected to the first mold material. It is preferable that the secondary grooves are formed simultaneously with the joining medium, and the secondary grooves are simultaneously formed with the first mold material, the second mold material, and the joining medium. In this case, the joining medium does not remain between the slit groove formed in the first mold material and the supply hole of the perforated mold material. Therefore, there is no need to selectively remove the joining medium after joining the first mold material and the perforated mold material. Therefore,
A honeycomb structure molding die can be more easily manufactured.

The joining medium is previously joined only to the lower surface of the first mold material, and the secondary groove is formed between the first mold material, the second mold material, and the joining medium. Can be formed simultaneously. In this case, as above,
A mold for forming a honeycomb structure can be easily manufactured.

Next, as in the invention according to claim 8, the joining medium for joining the first mold material and the perforated mold material is formed before the supply hole is formed in the perforated mold material. It is preferable that the supply holes are previously formed on the upper surface of the non-hole die material in the above state, and the supply holes are simultaneously formed in the non-hole die material and the bonding medium. Also in this case, the joining medium does not remain between the slit groove formed in the first mold material and the supply hole of the perforated mold material. Therefore, there is no need to selectively remove the joining medium after joining the first mold material and the perforated mold material. Therefore, the die for forming the honeycomb structure can be manufactured more easily.

Next, as in the invention according to claim 9, the joining medium for joining the first mold material and the perforated mold material is a supply medium formed on the perforated mold material. It is preferable that a communication hole is formed in advance at a position communicating with the hole by at least one of drilling, electric discharge machining, and pressing. Accordingly, there is no possibility that the cutting chips remain in the mold material having holes when the communication holes of the joining medium are formed.

Next, according to the tenth aspect of the present invention,
The joining medium is formed by joining a metal foil to a mold material by heat diffusion or brazing, or is formed on the mold material by plating or vapor deposition. It is preferably from 005 to 1 mm. Here, the mold material refers to the first mold material, the second mold material, a perforated mold material, or a non-perforated mold material. That is, the joining medium is formed by disposing a metal foil on the upper surface or the lower surface of the first mold material, the perforated mold material, or the like, and joining them by heat diffusion or brazing. Alternatively, the bonding medium is formed by forming a metal film on the upper surface or the lower surface of the first mold material, the perforated mold material, or the like by plating or vapor deposition such as PVD or CVD.

Thus, the first mold material and the second mold material are
The joining with the mold material or the joining between the first mold material and the perforated mold material can be performed more easily and reliably. The above-mentioned metal foil affects the diffusibility with the metal powder contained in the cemented carbide used in the present invention, and is mainly made of gold, silver, copper, nickel, etc. from the viewpoint of bondability and bonding strength governed by the metal powder. It is preferable that the component is a metal or an alloy.

Further, the thickness of the joining medium is set to 0.005
By setting the thickness to １1 mm, higher bonding strength can be obtained. That is, it is possible to prevent breakage from the joining medium portion and selective wear of the joining medium portion, and obtain a mold for forming a honeycomb structure having excellent durability.

When the thickness of the joining medium is less than 0.005 mm, the flatness of the joining interface between the opposing mold materials to be joined needs to be less than 0.005 mm. As a result, when a mold for forming a honeycomb structure having a size to be manufactured according to the present invention, which will be described in detail later, is manufactured, time and labor are significantly increased due to the area thereof, resulting in poor economic efficiency. Also,
If the flatness cannot be reduced to less than 0.005 mm, the adhesion between the bonding interfaces is hindered, and the bonding of the mold material becomes difficult, and there is a possibility that sufficient bonding strength cannot be obtained. On the other hand, if the thickness is more than 1 mm, the bonding medium is selectively worn due to fracture due to stress concentration on the bonding medium or extrusion of the material forming the honeycomb structure. May break from the portion of the bonding medium.

Next, as in the eleventh aspect of the present invention,
The first mold material, the second mold material, and the perforated mold material are preferably made of a cemented carbide. This makes it possible to easily and reliably maintain the dimensional accuracy in joining the mold materials. The above-mentioned cemented carbide is a hard sintered alloy obtained by blending a metal carbide powder and a metal powder and sintering them. As the cemented carbide, for example, there is a sintered metal mainly composed of tungsten carbide (WC) and solidified with cobalt (Co).

Next, as in the twelfth aspect of the present invention,
The above-mentioned cemented carbide is obtained by adding at least one or more metals of iron, cobalt and nickel to carbide powder composed of carbide of at least one or more metals belonging to groups 4a, 5a and 6a of the periodic table. %, And preferably a sintered alloy. That is, Ti, V, Cr, Z
At least one of iron, cobalt, and nickel is added to a carbide powder composed of carbide of at least one metal of at least one of r, Nb, Mo, Hf, Ta, and W so that the content is 3 to 30%. By sintering, the cemented carbide is obtained.

Thus, the processing of the slit groove and the joining of the mold materials can be performed more easily and reliably.
When each of the above-mentioned metals of iron, cobalt and nickel is added alone, the content is 3 to 30%. When a plurality of types of metals are added, the total content is 3 to 30%.
30%.

This has a direct effect on the proof stress of the mold material in the high temperature range when it is subjected to the joining process, and greatly affects the maintenance of the dimensional accuracy of the primary groove and the like already formed before the joining. Also,
It also affects the diffusibility with the joining medium and affects the joining properties and joining strength. That is, when the content is more than 30%, the material yield strength in a high-temperature region used for joining as described in detail below is low, and the weight of the material at the time of joining and the pressurization for improving the adhesion described in detail below are used. As a result, the dimensions of the primary groove and the like may change, and may not be established as a mold. On the other hand, when the content is 3
%, The diffusibility between the bonding medium and each mold material is reduced, and the bonding property and bonding strength may be reduced. Also, in this case, the toughness is reduced, the material is easily damaged when used as a mold, and the crack propagation is increased, so that extreme care is required in handling.

Next, as in the invention of claim 13,
A first mold material having a honeycomb-shaped through slit groove formed therein is joined to a perforated mold material having a supply hole for supplying a material, and the slit groove communicates with the supply hole. There is a mold for forming a honeycomb structure, which is characterized by being formed as follows.

In the honeycomb structure forming die, the slit groove directly communicates with the supply hole. Therefore, when the honeycomb structure is formed using the honeycomb structure forming die, the material supplied to the supply hole is directly supplied to the slit groove. That is, the material supplied to the supply hole is directly supplied to the slit groove while maintaining fluidity. Therefore, the material is uniformly supplied to the entire area of the slit groove, and there is no possibility that a problem such as distortion of the formed honeycomb structure occurs.

Next, as in the invention of claim 14,
The first mold material, the second mold material, and the perforated mold material are preferably made of a cemented carbide. This makes it possible to easily and reliably maintain the dimensional accuracy in joining the mold materials.

Next, as in the invention according to claim 15,
The above-mentioned cemented carbide is obtained by adding at least one or more metals of iron, cobalt and nickel to carbide powder composed of carbide of at least one or more metals belonging to groups 4a, 5a and 6a of the periodic table. %, And preferably a sintered alloy. As a result, the slit groove is more reliably formed, and a mold for forming a honeycomb structure in which the respective mold materials are more securely joined can be obtained.

Next, according to the sixteenth aspect of the present invention,
It is preferable that a joining medium is interposed between the first mold material and the second mold material and between the first mold material and the perforated mold material. This makes it possible to obtain a honeycomb structure forming mold in which the mold materials are more securely joined.

Next, according to the seventeenth aspect of the present invention,
The joining medium is formed by joining a metal foil to a mold material by heat diffusion or brazing, or is formed on the mold material by plating or vapor deposition. It is preferably from 005 to 1 mm. Here, the mold material refers to the first mold material, the second mold material, a perforated mold material, or a non-perforated mold material. Thereby, the joining of the first mold material and the second mold material or the joining of the first mold material and the perforated mold material can be performed more easily and reliably. The metal foil is preferably a metal or an alloy containing gold, silver, copper, nickel, or the like as a main component, from the viewpoint of bondability and bonding strength. The critical significance of the thickness of the joining medium is the same as in the case of the tenth aspect.

[0045]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 A method for manufacturing a honeycomb structure forming die according to an embodiment of the present invention will be described with reference to FIGS. The honeycomb structure forming die 1 manufactured in this example is shown in FIG.
As shown in the figure, a supply hole 131 for supplying a material,
It has a slit groove 15 which communicates with the supply hole 131 to form the material into a honeycomb shape.

As shown in FIG.
It comprises a process to a fifth process. In FIG. 1, (A-1) to
(E-1) is a perspective view in which the upper surfaces of the first to fourth processed bodies and the honeycomb structure forming die are directed upward, and (A-2) is a perspective view.
(E-2) is a perspective view with the lower surface facing upward.

That is, in the first step, a plurality of penetrating primary grooves 115 independent of each other are formed in the first mold material 11.
Is formed by wire electric discharge machining,
(FIG. 1 (A-1), (A-2)). Then, the second
In the process, the second mold material 12 is
1 to obtain a secondary processed body 102 (FIG. 1B
-1), (B-2)).

Next, in a third step, a plurality of independent secondary grooves 1
25 is formed by wire electric discharge machining,
03 (FIG. 1 (C-1)). At this time, the honeycomb-shaped slit groove 15 formed by the secondary groove 125 communicating with the primary groove 115 is formed in the first mold material 11 (FIG. 1C-2). (FIG. 3 (C)).

Next, in a fourth step, the supply holes 1
The mold material 13 having a hole 31 having the same shape as the first mold material 11
To obtain the fourth processed body 104 (FIG. 1 (D-
1), (D-2)). Next, in a fifth step, the second die material 12 is removed from the fourth processed body 104 to obtain the honeycomb structure forming die 1 (see FIG. 1 (E-
1), (E-2)).

In the first and third steps,
In forming the primary groove 115 and the secondary groove 125,
A small-diameter through hole is provided in the first mold material 11 or the secondary processing body 102, and a wire electrode is passed through the through hole. Then, electrical discharge machining is performed while relatively moving the wire electrode.
This is because only the end is left without processing so that the first mold material 11 and the like are not separated by the formation of the primary groove 115 and the like.

In the second step and the fourth step,
The first mold material 11 and the second mold material 12 or the first mold material 11 and the perforated mold material 13 are joined by a diffusion welding method. In the fifth step, the second mold material 1
2 is removed by surface grinding using a surface grinder.

Next, the operation and effect of this embodiment will be described. In the method for manufacturing the honeycomb structure forming mold 1 described above,
As described above, the perforated mold material 13 is directly joined to the lower surface of the first mold material 11 on which the honeycomb-shaped slit grooves 15 are formed, and then joined to the upper surface of the first mold material 11. The removed second mold material 12 is removed (FIG. 1 (D-
1), (D-2), (E-1), (E-2)).

Therefore, the slit groove 15 of the honeycomb structure forming die 1 obtained by the above manufacturing method is directly connected to the supply hole 131 as shown in FIG. Therefore, when forming the honeycomb structure, FIG.
The material supplied to the supply hole 131 indicated by the solid line in FIG. 3B is directly supplied to the slit groove 15 indicated by the solid line in FIG. That is, the material supplied to the supply hole is directly supplied to the slit groove while maintaining fluidity. As a result, the material is uniformly supplied to the entire area of the slit groove 15. Therefore, there is no possibility that a problem such as distortion of the formed honeycomb structure occurs.

FIG. 3 (D) is a diagram showing the structure of D in FIG. 1 (D-2).
FIG. 2 is a cross-sectional view taken along line D of FIG.
Since the honeycomb structure is being manufactured, the completed honeycomb mold for forming a honeycomb structure 1 does not have the cross section shown in FIG. In the fifth step, since the second mold material 102 is removed by surface grinding, the second mold material 102 can be easily removed.

As described above, according to the present embodiment, a honeycomb structure forming mold capable of forming a honeycomb structure free from defects such as distortion can be manufactured by wire electric discharge machining.

Embodiment 2 As shown in FIG. 4, this embodiment shows a more specific example of the honeycomb structure forming mold of Embodiment 1 and a method of manufacturing the same. The honeycomb structure forming die 1 of this example is shown in FIG.
As shown in the figure, the mold is made up of a square plate-shaped perforated mold material 13 and a circular plate-shaped first mold material 11. The perforated mold material 13, the first mold material 11, and a second mold material described later are made of a steel material for a mold.

The outer shape of the perforated mold blank 13 is determined on the basis of the mounting dimensions to the molding machine.
3 is 200 mm square. On the other hand, the first mold material 1
1 has a diameter of about 130 mm. The thickness of the honeycomb structure forming die 1 is about 20 mm.

As shown in FIG. 4C, a number of hexagonal honeycomb-shaped slit grooves 15 are formed in the first die material 11. The width of the slit groove 15 is
0.1 mm. On the other hand, in the perforated mold 13, a large number of supply holes 131 for supplying a material having a diameter of 1.0 mm are provided corresponding to the intersections of the slit grooves 15 (FIG. 4).
(C broken line). The supply hole 131 is provided in the slit groove 1.
The material supplied from the supply hole 131 is supplied to the slit groove 15. Note that FIG.
In FIG. 2A, reference numeral 139 denotes a mounting hole for mounting the honeycomb structure forming die 1 to a forming machine.

The method of manufacturing the honeycomb structure forming die 1 is basically the same as the method of manufacturing the first embodiment. In the case of this example, in the first step shown in the first embodiment, a primary groove having a substantially half shape of the hexagonal honeycomb is formed by wire electric discharge machining using a tungsten wire electrode having a diameter of 0.07 mm. It is formed on the first mold material 11 of a circular plate. In the second step, a second mold material is joined to the primary work body by using a diffusion welding method. In the third step, a secondary groove is formed by the same wire electric discharge machining as described above.

In the fourth step, the first mold material 1
On the lower surface of 1, a square plate-shaped perforated mold material 13 provided with a supply hole 131 in advance is joined by a diffusion welding method to obtain a fourth processed body. Next, in a fifth step, the second die material of the quaternary workpiece is removed by surface grinding using a surface grinder. Thus, the honeycomb structure forming die 1 shown in FIGS. 4A and 4B is obtained. Other configurations are the same as those of the first embodiment. In the case of this embodiment, the same operation and effect as those of the first embodiment are obtained.

In this example, the diameter is 0.07 mm.
A slit groove having a groove width of 0.1 mm was formed by using the wire electrode of (1). However, the diameter of the wire electrode was further reduced to form a thinner slit groove of, for example, 0.075 mm and 0.05 mm. You can also. Also,
Although the steel material for the mold is used as the above-mentioned perforated mold material, the first mold material, and the second mold material, other materials such as a sintered metal may be used.

In the second and fourth steps of the first and second embodiments, the first mold material and the second mold material, or the first mold material and the perforated mold material are combined. Although the diffusion welding method was used for the joining, other joining methods such as a brazing method and an adhesive method may be used.

Embodiment 3 In this embodiment, as shown in FIG. 5, in a first step and a third step, a large number of primary grooves 115 and secondary grooves 125 are connected in a single stroke without being independent from each other. This is an example of forming by forming. That is, the primary groove and the secondary groove of the first embodiment are independent of each other (FIGS. 1A-1 and 1C-2).
In contrast to 1)), the primary groove 115 and the secondary groove 125 of this example are used.
Are connected by connecting grooves 116 and 126 as shown in FIGS. 5 (A-1) and 5 (C-1).

In the manufacturing method of the honeycomb structure forming die 1 of this embodiment, in the first step, FIGS. 5A-1 and 5A-1
As shown in 2), a large number of penetrating primary grooves 115 connected to the first mold material 11 in one stroke are formed by wire electric discharge machining.

In the third step, the secondary work 1
02 (FIGS. 5 (B-1) and 5 (B-2)), a plurality of penetrating secondary grooves 125 connected in a single stroke are formed by wire electric discharge machining (FIG. 5 (C-1)). . At this time, the secondary groove 125 is formed in the first mold material 11 by the primary groove 1.
By forming the honeycomb-shaped slit groove 15 formed by communicating with the tertiary processing body 10
No. 3 is obtained (FIG. 5 (C-2)).

The second, fourth and fifth steps other than the first and third steps are the same as in the first embodiment. 5 (D-1), (D-2)
Represents the quaternary workpiece 104 obtained by the fourth step, and FIGS. 5E-1 and 5E-2 represent the honeycomb structure forming die 1 finally obtained.

The method for manufacturing the honeycomb structure forming mold 1 of the present embodiment includes a first mold blank 1 in a first step and a third step.
A plurality of penetrating primary grooves 115 or secondary grooves 125 connected to the first or second mold material 102 in a single stroke are formed (FIGS. 5A-1, 5A-2, and 5C). -1)).

For this reason, it is not necessary to provide a large number of small-diameter through holes used as a starting point in wire electric discharge machining. In other words, it is sufficient to provide one location on the first mold material 11 and one location on the secondary processing body 102. Further, it is not necessary to perform a setup operation every time the primary groove 115 or the secondary groove 125 is processed by one line. Therefore, it is possible to manufacture the honeycomb structure forming mold with higher production efficiency. In addition, the third embodiment has the same functions and effects as the first embodiment.

In the fifth step of the first to third embodiments, the removal of the second mold material was performed by surface grinding using a surface grinder, but other methods such as wire electric discharge machining may also be used. Can be removed. Furthermore, the shape of the honeycomb of the slit groove is not limited to a hexagon, but may be another shape such as a square or a circle.

Embodiment 4 As shown in FIGS. 6 to 8, this embodiment relates to the joining of the first mold material 11 and the second mold material 12, and the first mold material 11 and the perforated mold material. 13 is an example in which the bonding medium 13 is joined by interposing a bonding medium 21 or 22 on the bonding surface. 6 to 8
, (A-1) to (F-1) are top views, and (A-
2) to (F-2) are bottom views, and (A-3) to (F-3).
Are (A-1) to (F-1) or (A-2) to (F-
It is explanatory drawing equivalent to the JJ line arrow cross section of 2).

A method for manufacturing the honeycomb structure forming mold of this embodiment will be described with reference to FIGS. First, in the first step, FIGS. 6 (A-1), (A-2), (A-3)
As shown in (1), a primary groove 115 is formed in the first mold material 11 to obtain a primary workpiece 101. The above first mold material 11
Consists of cemented carbide. The cemented carbide is a sintered metal containing tungsten carbide (WC) as a main component and solidified with cobalt, and has a cobalt content of about 12%. The second
The mold material 12 and the perforated mold material 13 are also made of the same cemented carbide.

Next, in the second step, FIG.
1), (B-2) and (B-3), as shown in FIG.
The second die material 12 is bonded to the upper surface of the die material 11 with a bonding medium 21 made of nickel (Ni) foil interposed therebetween. In joining, the flatness of each mold material and the joining medium 21 is finished to about 0.2 mm or less in order to improve the adhesion. Then, the joining medium 21 is interposed on the joining surface between the first mold material 11 and the second mold material 12, and the creep temperature of the joining medium 21, that is, about 1/2 or more of the inherent melting temperature and Heat below the melting temperature. Also,
Heating is performed in a vacuum atmosphere so that no oxide is generated at the bonding interface and the attached oxide is evaporated at a specific vapor pressure. Further, in order to improve the adhesion at the bonding interface, pressure is applied at the time of raising or lowering the temperature. However, from the viewpoint of maintaining dimensional accuracy, which is affected by the high-temperature strength of the die material, a maximum of 10
The pressure is set to 0 MPa or less.

As a result, the secondary processed body 102 is obtained. Further, from the viewpoint of bonding strength, the thickness of the bonding medium 21 is set to about 50 μm. Further, since the bonding medium 21 is annealed under a high temperature condition as described above, its hardness does not pose any particular problem. For example, as the hardness of the joining medium 21, a material of １ ／ H to H material is sufficient.

Next, in the third step, FIG.
As shown in (1), (C-2) and (C-3), a secondary groove 125 is formed in the secondary processing body 102, and the tertiary processing body 1 is formed.
Get 03. At this time, a honeycomb-shaped slit groove 15 is formed in the first mold material 11 (see FIG. 7C
-2)).

Next, in the fourth step, FIG.
1), as shown in (D-2) and (D-3),
The perforated mold material 13 is joined to the lower surface of the mold material 11 with a joining medium 22 interposed therebetween. The bonding medium 22 and the bonding method are the same as the bonding medium 21 and the bonding method used in the second step. As a result, the fourth processed body 104 is obtained. At this time, the slit groove 15 is in the first mold material 1.
1 is closed by the joining medium 22, and the supply hole 131 is also closed by the joining medium 22 from the upper surface of the perforated mold material 13 (FIG. 7D-
3)). Therefore, the supply hole 131 and the slit groove 15 are not in communication.

Next, in a fifth step, FIG.
As shown in 1), (E-2) and (E-3), the second mold material 12 and the bonding medium 21 on the lower surface thereof are removed from the quaternary workpiece 104. Next, the joining medium 22 that is blocking the communication between the supply hole 131 and the slit groove 15 is selectively removed by, for example, fluid polishing. This gives
As shown in FIGS. 8 (F-1), 8 (F-2) and 8 (F-3), the supply hole 131 and the slit groove 15 communicate with each other, and the honeycomb structure forming die 1 is completed. Other configurations are the same as those of the first embodiment.

In the case of this embodiment, the joining media 21 and 22
Therefore, the joining between the first mold material 11 and the second mold material 12 and the joining between the first mold material 11 and the perforated mold material 13 can be performed easily and reliably. Since the joining media 21 and 22 are made of nickel foil, the joining between the first mold material 11 and the second mold material 12 and the joining between the first mold material 11 and the perforated mold material 13 are performed. , Can be performed more easily and reliably. In addition, the joining media 21 and 22
Since the thickness is about 50 μm, higher bonding strength can be obtained.

The first mold material 11, the second mold material 12, and the perforated mold material 13 are made of a cemented carbide having a cobalt content of about 12%. The proof stress of the material is also sufficiently ensured, and dimensional accuracy can be easily and reliably maintained in joining the mold materials. Also, since it has moderate toughness, it is hardly damaged when used as a mold, and no special care is required for handling the mold for forming a honeycomb structure. In addition, the third embodiment has the same functions and effects as the first embodiment.

Fifth Embodiment As shown in FIGS. 9 to 11, a fifth embodiment
This is an example in which joining media 21 and 22 are joined in advance to both surfaces of the sheet. Then, the primary groove 115 is inserted into the first mold material 11.
And the bonding media 21 and 22 at the same time (see FIG. 9B
-3)) Also, a secondary groove 125 is formed simultaneously in the secondary processing body 102 and the bonding media 21 and 22 (FIG. 10).
(D-3)). 9 to 11, (A-1) to
(F-1) is a top view, (A-2) to (F-2) are bottom views, and (A-3) to (F-3) are (A-1) to (F-
FIG. 1 is an explanatory view corresponding to a cross section taken along line KK of (A-2) to (F-2).

A method for manufacturing the honeycomb structure forming mold of this embodiment will be described with reference to FIGS. First, the first
In the process, FIG. 9 (A-1), (A-2), (A-
As shown in 3), the joining media 21 and 22 are joined to both surfaces of the first mold material 11 in advance, and FIGS.
2) and (B-3), the primary groove 115 is formed. At this time, the primary groove 115 is
And the bonding media 21 and 22 bonded to both surfaces thereof at the same time. Thereby, the primary processed body 101 is obtained.
The materials of the first mold material 11, the second mold material 12, and the perforated mold material 13, and the materials and thicknesses of the joining media 21 and 22 are the same as those in the fourth embodiment. .

Next, in the second step, FIG.
1), (C-2) and (C-3), the first
The second mold material 12 is joined to the upper surface of the mold material 11 via the joining medium 21. The joining method at this time is
This is the same as the case of the fourth embodiment. Thereby, the secondary processed body 102 is obtained.

Next, in the third step, FIG.
As shown in (1), (D-2) and (D-3), the secondary grooves 12 are formed in the secondary processing body 102 including the bonding media 21 and 22.
5 to form a tertiary processed body 103. At this time, honeycomb-shaped slit grooves 15 are formed in the first mold material 11 and the joining medium 22 on the lower surface thereof.
(D-2)).

Next, in the fourth step, FIG.
1), (E-2) and (E-3) as shown in FIG.
The perforated mold material 13 is joined to the lower surface of the mold material 11 via a joining medium 22. This joining method is the same as in the second step. As a result, the fourth processed body 104 is obtained.

Next, in a fifth step, FIG.
1) As shown in (F-2) and (F-3), the second mold material 12 and the bonding medium 21 on the lower surface thereof are removed from the quaternary workpiece 104. Thus, the honeycomb structure molding die 1 is completed. Others are the same as the fourth embodiment.

In this case, the joining medium 22 does not remain between the slit groove 15 formed in the first mold material 11 and the supply hole 131 of the perforated mold material 13. . Therefore, there is no need to selectively remove the joining medium 2 as in the fourth embodiment. Therefore, the honeycomb structure molding die 1 can be manufactured more easily. In addition, the fourth embodiment has the same functions and effects as the fourth embodiment.

Embodiment 6 As shown in FIGS. 12 to 15, this embodiment is directed to
This is an example in which the bonding medium 22 is bonded in advance to the upper surface of the third medium.
12 to 15, (a-1) to (F-1) are top views, (a-2) to (F-2) are bottom views, and (a-3) to (A-3).
(F-3) is (a-1) to (F-1) or (a-
It is explanatory drawing equivalent to the KK line arrow cross section of 2)-(F-2).

A method for manufacturing the honeycomb structure forming die of this embodiment will be described with reference to FIGS. First, as shown in FIG. 12, the die material 13 with holes to which the bonding medium 22 has been bonded is prepared in advance.

That is, FIGS. 12 (a-1), (a-2),
As shown in (a-3), the non-perforated mold material 130 in the perforated mold material 13 before the supply hole 131 is formed.
The joining medium 22 is joined to the upper surface of the substrate. Next, FIG.
As shown in (b-1), (b-2) and (b-3), the supply hole 1 is simultaneously supplied to the non-perforated mold material 130 and the joining medium 22.
31 are formed. As a result, a perforated mold material 13 having the supply holes 131 in which the bonding medium 22 is formed on the upper surface excluding the supply holes 131 is obtained.

The following method is also available as a method for producing the perforated mold material 13 to which the joining medium 22 has been joined in advance. That is, the joining medium 22 is used for the perforated mold material 1.
A communication hole is formed at a position communicating with the supply hole 131 formed in advance by using at least one of drilling, electric discharge machining, and press working, and is joined to the upper surface of the perforated mold material 13. Alternatively, the joining member 22 having the communication hole formed as described above is interposed between the first mold material 11 and the perforated mold material 13 before joining them. As a result, a perforated mold material 13 having a supply hole 131 in which the joining medium 22 is formed on the upper surface excluding the supply hole 131 is obtained.

In the first step of the present manufacturing method, FIG.
As shown in (A-1), (A-2) and (A-3), the joining medium 21 is joined to the upper surface of the first mold material 11 in advance.
As shown in FIGS. 13 (B-1), (B-2) and (B-3), a primary groove 115 is formed. At this time, the primary groove 11
5 is simultaneously formed on the mold material 11 and the joining medium 21 joined to the upper surface thereof. Thereby, the primary processed body 101 is obtained. The materials of the first mold material 11, the second mold material 12, and the perforated mold material 13, and the materials and thicknesses of the joining media 21 and 22 are the same as those in the fourth embodiment. .

Next, in the second step, FIG.
1), (C-2) and (C-3), the first
The second mold material 12 is joined to the upper surface of the mold material 11 via the joining medium 21. The joining method at this time is
This is the same as the case of the fourth embodiment. Thereby, the secondary processed body 102 is obtained.

Next, in the third step, FIG.
1), (D-2) and (D-3), a secondary groove 125 is formed in the secondary processing body 102 including the bonding medium 21 to obtain a tertiary processing body 103. At this time, the first
Honeycomb-shaped slit grooves 15 are formed in the mold material 11 and the bonding medium 21 (FIG. 14D-2).

Next, in a fourth step, FIG.
1), (E-2) and (E-3) as shown in FIG.
The perforated mold material 13 is joined to the lower surface of the mold material 11 via a joining medium 22. That is, the die material 13 with holes having the bonding medium 22 formed on the upper surface (FIGS. 12 (b-1), (b-2), and (b-3)) prepared in advance as described above.
Is bonded to the lower surface of the first die blank 11. This joining method is the same as in the second step. As a result, the fourth processed body 104 is obtained.

Next, in a fifth step, FIG.
1) As shown in (F-2) and (F-3), the second mold material 12 and the bonding medium 21 on the lower surface thereof are removed from the quaternary workpiece 104. Thus, the honeycomb structure molding die 1 is completed. Others are the same as the fourth embodiment.

Also in this case, the joining medium 22 does not remain between the slit groove 15 formed in the first mold material 11 and the supply hole 131 of the perforated mold material 13. . Therefore, there is no need to selectively remove the joining medium 2 as in the fourth embodiment. Therefore, the honeycomb structure molding die 1 can be manufactured more easily. In addition, the fourth embodiment has the same functions and effects as the fourth embodiment.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a method for manufacturing a honeycomb structure forming mold according to a first embodiment.

FIG. 2 is a perspective view of a honeycomb structure forming mold according to the first embodiment.

FIG. 3A is a sectional view taken along line AA of FIG. 1E-2,
(B) A sectional view taken along the line BB in (A), and C in (C) and (A).
FIG. 1D is a cross-sectional view taken along a line C, and FIG. 1D is a cross-sectional view taken along a line D-D in FIG.

4A is a plan view, FIG. 4B is a side view, and FIG. 4C is an explanatory view of a slit groove and a supply hole in Embodiment 2 of the present invention.

FIG. 5 is an explanatory view of a method for manufacturing a honeycomb structure forming mold according to a third embodiment.

FIG. 6 is an explanatory view of a manufacturing method (first to second steps) of a die for forming a honeycomb structure according to a fourth embodiment.

FIG. 7 is an explanatory diagram of a method for manufacturing a honeycomb structure forming mold (third step to fourth step) in a fourth embodiment.

FIG. 8 is an explanatory diagram of a method (fifth step) of manufacturing a die for forming a honeycomb structure according to the fourth embodiment.

FIG. 9 is an explanatory view of a method (first step) of manufacturing a die for forming a honeycomb structure according to a fifth embodiment.

FIG. 10 is an explanatory view of a method for manufacturing a honeycomb structure forming die (secondary to third steps) in a fifth embodiment.

FIG. 11 is an explanatory view of a method (fourth step to fifth step) of manufacturing a honeycomb structure forming die according to the fifth embodiment.

FIG. 12 is an explanatory view of a method for manufacturing a die material with holes in Embodiment 6;

FIG. 13 is an explanatory view of a method (first step) of manufacturing a die for forming a honeycomb structure according to the sixth embodiment.

FIG. 14 is an explanatory diagram of a method for manufacturing a honeycomb structure forming die (secondary to third steps) in a sixth embodiment.

FIG. 15 is an explanatory view of a method (fourth step to fifth step) of manufacturing a die for forming a honeycomb structure according to the sixth embodiment.

FIG. 16 is an explanatory view of a method of manufacturing a honeycomb structure forming mold in a conventional example.

17A is a sectional view taken along line EE of FIG. 16D-1, FIG. 17B is a sectional view taken along line FF of FIG. 16B, FIG.
FIG. 3 is a sectional view taken along line GG of FIG.

FIG. 18 is an explanatory view of (A) a slit groove and (B) a corresponding secondary groove for explaining a material flow at the time of molding in a conventional honeycomb structure molding die.

[Explanation of symbols]

 1. . . 101. Mold for forming honeycomb structure . . Primary processed body, 102. . . Secondary processed body, 103. . . Tertiary processed body, 104. . . Fourth work body, 11. . . 1st mold material, 115. . . Primary groove, 12. . . Second mold material, 125. . . 12. secondary groove, . . Perforated mold material, 131. . . Supply holes, 15. . . Slit grooves, 21, 22,. . . Joining media,

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification FI FI Theme Court ゛ (Reference) C22C 29/10 C22C 29/10 (72) Inventor Masakatsu Fujita 1-1-1 Showa-cho, Kariya-shi, Aichi Pref. Inside Denso Corporation (72) Inventor Tohru Takeno 1-1-1, Showa-cho, Kariya-shi, Aichi Pref. Inside Denso Corporation (72) Inventor Nobuhiko Nagai 1-1-1, Showa-cho, Kariya-shi, Aichi Pref.

Claims (17)

[Claims] 1. A method for manufacturing a honeycomb structure forming mold having a supply hole for supplying a material and a slit groove communicating with the supply hole for forming the material into a honeycomb shape. The method includes a first step of forming a plurality of independent primary grooves formed in a first mold material by wire electric discharge machining to obtain a primary work body; A second step of joining to the upper surface of the workpiece to obtain a secondary workpiece, and forming a plurality of mutually independent secondary grooves in the secondary workpiece by wire electric discharge machining; A third step of obtaining a tertiary processed body by forming the honeycomb-shaped slit groove formed by communicating the secondary groove with the primary groove in the first mold material;
A fourth step of joining the perforated mold material having the supply holes to the lower surface of the first mold material to obtain a fourth work body, and a fourth step of removing the second mold material from the fourth work body. A method for manufacturing a honeycomb structure forming mold, comprising five steps. 2. A method for manufacturing a honeycomb structure forming mold having a supply hole for supplying a material and a slit groove communicating with the supply hole for forming the material into a honeycomb shape. The method comprises: a first step of forming a plurality of penetrating primary grooves connected to the first mold material in a single stroke by wire electric discharge machining to obtain a primary work body; A second step of joining the upper surface of the primary processing body to obtain a secondary processing body, and forming a plurality of penetrating secondary grooves connected to the secondary processing body in a single stroke by wire electric discharge machining. At this time, a third step of obtaining a tertiary processed body by forming the honeycomb-shaped slit groove formed by the secondary groove communicating with the primary groove in the first mold material. And a perforated mold material having the supply hole is provided on the lower surface of the first mold material. A method of manufacturing a honeycomb structure forming mold, comprising: a fourth step of joining to obtain a fourth work body; and a fifth step of removing the second mold material from the fourth work body. . 3. The method for manufacturing a honeycomb structure forming mold according to claim 1, wherein in the fifth step, the second mold material is removed by surface grinding. 4. The method for manufacturing a honeycomb structure forming die according to claim 1, wherein the fifth step removes the second die material by wire cutting. 5. The method according to claim 1, wherein:
The method for manufacturing a die for forming a honeycomb structure, wherein the slit groove is one of a square, a hexagon, and a circle. 6. The method according to claim 1, wherein:
The joining between the first mold material and the second mold material and the joining between the first mold material and the perforated mold material are performed by interposing a joining medium on a joining surface. A method for manufacturing a honeycomb structure forming mold. 7. The bonding medium according to claim 6, wherein the bonding medium is bonded to both surfaces of the first mold material in advance, and the primary groove is simultaneously formed in the first mold material and the bonding medium. The secondary groove is formed between the first mold material and the second mold material.
A method for manufacturing a mold for forming a honeycomb structure, comprising simultaneously forming a mold material and the bonding medium. 8. The non-perforated mold according to claim 6, wherein the joining medium for joining the first mold material and the perforated mold material is a state before the supply hole is formed in the perforated mold material. A method for manufacturing a honeycomb structure forming die, wherein the die is preliminarily bonded to an upper surface of a die material, and the supply hole is formed simultaneously with the non-hole die material and the bonding medium. 9. The method according to claim 6, wherein the joining medium for joining the first mold material and the perforated mold material is located at a position communicating with a supply hole formed in the perforated mold material. A method for manufacturing a die for forming a honeycomb structure, wherein a communication hole is formed in advance by at least one of drilling, electric discharge machining, and press working. 10. The joining medium according to claim 6, wherein the joining medium is formed by joining a metal foil to a mold material by heat diffusion or brazing, or by plating or vapor deposition. A method for manufacturing a die for forming a honeycomb structure, wherein the die is formed of a material, and the thickness of the bonding medium is 0.005 to 1 mm. 11. The honeycomb structure according to claim 1, wherein the first mold material, the second mold material, and the perforated mold material are made of a cemented carbide. A method for manufacturing a body molding die. 12. The cemented carbide according to claim 11, wherein the cemented carbide is made of iron, cobalt, nickel, and carbide powder composed of a carbide of at least one metal of metals belonging to groups 4a, 5a and 6a of the periodic table. 3. A method for manufacturing a honeycomb structure forming die, wherein a sintered alloy is obtained by adding at least one kind of metal of 3 to 30%. 13. A first mold material having a honeycomb-shaped penetrating slit groove formed therein, and a perforated mold material having a supply hole for supplying a material are joined to each other. A die for forming a honeycomb structure, wherein the die is formed to communicate with a supply hole. 14. The mold for forming a honeycomb structure according to claim 13, wherein the first mold material, the second mold material, and the perforated mold material are made of cemented carbide. 15. The cemented carbide according to claim 14, wherein the cemented carbide is made of iron, cobalt, nickel with respect to a carbide powder comprising a carbide of at least one metal belonging to Groups 4a, 5a and 6a of the periodic table. 3. A mold for forming a honeycomb structure, wherein 3 to 30% of at least one metal is added to form a sintered alloy. 16. The method according to claim 13, wherein the first mold material and the second mold material and the first mold material and the perforated mold material are different from each other. A mold for forming a honeycomb structure, wherein a joining medium is interposed between the molds. 17. The bonding medium according to claim 16, wherein the bonding medium is formed by bonding a metal foil to a mold material by heat diffusion or brazing, or formed on the mold material by plating or vapor deposition. The thickness of the joining medium is 0.0
A mold for forming a honeycomb structure, which has a diameter of 0.5 to 1 mm.