JP2001079821A - Mold for molding honeycomb structure, its manufacture and device for processing channel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mold for molding a honeycomb structure which has high productivity and can perform processing of a channel with high accuracy, a method for manufacturing the mold, and a device for processing channel. SOLUTION: Feeding holes 2 are formed from one face 52 of a base plate 5 and a base channel 3 with a wider channel width than that of a molding channel 4 is formed from another face 52 to communicate the base channel 3 with the feeding holes 2 in the midway of the thickness direction of the base plate 5 and then, a top plate 6 is bonded on a base channel forming face 51 where the base channel 3 is opened on the base plate 5 and then, it is irradiated with high density energy beams so as to pass them through from the surface of the top plate 6 to the base channel 3 to process the molding channel 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a die for extruding a ceramic honeycomb structure used for a catalyst carrier or the like of an exhaust gas purifying apparatus for an automobile, and a method for forming a groove.

[0002]

2. Description of the Related Art Hitherto, for example, Japanese Patent Application Laid-Open No. 11-073504 has proposed a method of manufacturing a mold for forming a honeycomb structure. This is a method of manufacturing a die for forming a honeycomb structure using a divided plate-shaped metal block body by a wire electric discharge machining technique and a joining technique.

[0003]

However, in order to form an ultra-fine groove by wire electric discharge machining, it is necessary to use an ultra-fine wire, and the machining speed is greatly reduced. Further, in order to obtain a high-precision forming groove, it is necessary to perform finishing processing after roughing, and it is necessary to perform a plurality of processings on the same forming groove, so that productivity is extremely deteriorated. On the other hand, as a processing method with high productivity, there is a method of irradiating a metal material with a high-density energy beam. However, in the groove processing using the high-density energy beam, there is a problem in that the precision of the forming groove is deteriorated due to the influence of the melt or the like by the high-density energy beam.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned conventional problems, and has a high productivity and a highly accurate groove forming die for forming a honeycomb structure, a method of manufacturing the same, and a groove. It is intended to provide a processing device.

[0005]

According to a first aspect of the present invention, there is provided a supply hole for supplying a material, a grid-like forming groove for forming a material into a honeycomb shape, and the supply hole along the shape of the forming groove. And a lower groove disposed between the base plate and the base plate, wherein the supply hole is formed from one surface of the base plate and a groove width is formed from the other surface to be smaller than the forming groove. Forming the lower groove having a large width, communicating the lower groove with the supply hole in the thickness direction of the base plate, and then joining the upper plate to the lower groove forming surface of the base plate where the lower groove is opened, A method for manufacturing a mold for forming a honeycomb structure, which comprises irradiating a high-density energy beam from the surface of the upper plate to the lower groove to process the forming groove.

It is most remarkable in the present invention that the lower groove having a groove width wider than the molding groove is provided in the base plate so that the lower plate is transmitted from the surface of the upper plate joined to the lower groove forming surface to the lower groove. This is to process the above-mentioned forming groove by irradiating a high-density energy beam.

Various beams such as a laser beam and an electron beam can be used as the high-density energy beam. Further, as the upper plate, a steel plate such as carbon steel, ceramics such as alumina, or the like can be used.

Next, the operation of the present invention will be described. In the present invention, as described above, a lower groove having a groove width wider than the forming groove is previously provided, and a material in which the upper plate is covered is used. Then, the high-density energy beam is irradiated from the front side of the upper plate. Therefore, the high-density energy beam can be irradiated so as to penetrate into the lower groove having a wide groove width. Therefore, it is possible to easily obtain a beam diameter and an output condition suitable for the forming accuracy of the forming groove, and to satisfactorily remove the melt and obtain a very accurate groove width. .

The high-density energy beam has much higher productivity than conventional wire electric discharge machining. Further, since the beam diameter, output, and the like of the high-density energy beam can be easily controlled, the width of the molding groove to be obtained can be easily changed. Therefore, it is possible to easily cope with manufacturing a plurality of honeycomb structure forming dies having different groove widths.

Therefore, according to the present invention, productivity is high,
In addition, it is possible to provide a method for manufacturing a honeycomb structure forming die capable of performing high-precision groove processing.

Next, as in the second aspect of the present invention, it is preferable that the cross-sectional area of the lower groove is at least 2.5 times the cross-sectional area of the forming groove. If the cross-sectional area of the lower groove is less than 2.5 times the cross-sectional area of the forming groove, a melt may remain in the lower groove or the forming groove during processing by high-density energy beam irradiation. There is a problem.

Further, as in the invention according to claim 3, the forming groove is processed while supplying an assist gas to the irradiated portion of the high-density energy beam from at least the lower groove side opposite to the irradiation side. It is preferred to do so. As the assist gas, for example, air, oxygen, argon, or the like can be used.

[0013] In this case, the assist gas is supplied by melting the molten material by the irradiation of the high-density energy beam.
It has the effect of discharging and removing to the irradiation side of the high-density energy beam, that is, to the surface side of the upper plate. Therefore, the groove processing by the high-density energy beam can be performed without being affected by the residual of the molten material and the like, and a more accurate groove width can be obtained.

Next, the assist gas is also supplied from the irradiation side while securing the flow of the assist gas supplied from the lower groove side to the irradiation portion to the irradiation side. Is preferred. In this case, the melt discharged on the surface side of the upper plate can be efficiently scattered, and the groove machining accuracy can be further improved.

According to a fifth aspect of the present invention, the assist gas is supplied from the lower groove side by using a movable nozzle, and the nozzle is moved with the movement of the high-density energy beam. It is preferable to supply the assist gas while performing the above. In this case, by always disposing the nozzle at the portion irradiated with the high-density energy beam, the supply of the assist gas can be concentrated on a limited portion, and the supply pressure of the assist gas can be easily increased. .

According to a sixth aspect of the present invention, a shielding plate having an opening around the high-density energy beam irradiating portion is disposed on the surface of the upper plate, and the shielding plate is attached to the high-density energy beam. The forming groove can be processed while moving along with the movement. In this case, it is possible to suppress the flow of the assist gas from the already-formed processing groove and to concentrate the flow of the assist gas on the high-density energy beam irradiation portion. Thereby, the effect of discharging and removing the melt by the assist gas can be further enhanced.

After the formation of the lower groove, it is preferable to apply an anti-adhesion agent to the inner wall of the lower groove to prevent the molten material from adhering. In this case, even if the melt that has come into contact with the inner wall of the lower groove may adhere to the inner wall of the lower groove, the inner wall of the lower groove can be easily returned to a healthy state by removing the entirety of the adhesion preventing agent after processing. Examples of the anti-adhesion agent include a brazing filler metal that can be melted and removed at a relatively low temperature, and a welding spatter preventing liquid.

Next, the invention of claim 8 provides a supply hole for supplying a material, a grid-like forming groove for forming the material into a honeycomb shape, and the supply hole along the shape of the forming groove. An apparatus for processing the forming groove of the honeycomb structure forming mold having a lower groove disposed between the supply groove and the lower groove, wherein the supply hole and the lower groove are formed in advance and the lower surface of the lower groove is formed. A beam irradiating means for irradiating a high-density energy beam to a mold material having an upper plate for forming the forming groove so as to pass through the lower groove from the surface of the upper plate; A moving means for moving along the lower groove, and a gas supply means for supplying an assist gas to the irradiated portion of the high-density energy beam from at least the lower groove side opposite to the irradiation side. Honeycomb structure In die groove processing apparatus.

The most notable feature of the groove processing apparatus of the present invention is that it has a beam irradiation means for irradiating the high-density energy beam and a moving means for moving the beam, and supplies an assist gas from the lower groove side. It is to have gas supply means. By using the groove processing apparatus of the present invention, the above-described excellent manufacturing method can be easily implemented.

Next, it is preferable that the beam diameter and the output of the high-density energy beam emitted from the beam irradiation means are changeable. In this case, a high-density energy beam having an optimum beam diameter can be fired at an optimum output according to a depth and a groove width of a forming groove to be obtained. Even if manufacturing conditions change, excellent accuracy can always be obtained.

According to a tenth aspect of the present invention, the gas supply means ensures that the assist gas supplied from the lower groove side to the irradiation portion flows toward the irradiation side, and also from the irradiation side. It is preferable that an assist gas be supplied. Specifically, it can be realized by disposing a gas supply means also in the beam irradiation means. In this case, similarly to the above, the molten material discharged to the surface side of the upper plate can be efficiently scattered.
Groove machining accuracy can be improved.

Further, as in the eleventh aspect of the present invention, the gas supply means has a movable nozzle for supplying an assist gas from the lower groove side. It is preferable to be provided so as to be movable with the movement of. In this case, by always disposing the nozzle at the portion irradiated with the high-density energy beam, the supply of the assist gas can be concentrated on a limited portion, and the supply pressure of the assist gas can be easily increased. .

It is preferable that the nozzle is provided coaxially with the beam irradiation means. In this case, the nozzle can reliably follow the movement of the high-density energy beam.

Further, as in the invention of claim 13, a shielding plate having an opening around the high-density energy beam irradiation portion is arranged on the surface of the upper plate, and the shielding plate is provided with the high-density energy beam. It is also possible to configure so that the above-mentioned forming groove is processed while moving along with the movement. In this case, as described above, it is possible to suppress the flow of the assist gas from the already-formed processing groove and concentrate the flow of the assist gas on the high-density energy beam irradiation portion.

Next, there is the following invention as a die for forming a honeycomb structure obtained by the above-mentioned excellent manufacturing method.
That is, a supply hole for supplying a material, a grid-like forming groove for forming a material into a honeycomb shape, and the supply hole along the shape of the forming groove. In the die for forming a honeycomb structure having a lower groove disposed between the lower groove and the lower groove, the lower groove has a cross-sectional area of a groove that is at least 2.5 times wider than a cross-sectional area of the groove of the forming groove. There is a die for forming a honeycomb structure, characterized in that the groove is processed by irradiation of a high-density energy beam and a vertical streak is formed on an inner wall of the groove. Since the honeycomb structure forming die can be manufactured by the above-described excellent manufacturing method, it can be excellent in dimensional accuracy and low in cost.

Further, as in the fifteenth aspect of the present invention, the cross-sectional shape of the forming groove can be a tapered shape in which the incident side of the high-density energy beam is narrow.

Further, as in the sixteenth aspect of the present invention, the forming groove forming portion is made of carbon steel, and a hardened layer which is rapidly solidified after melting is formed on the inner wall of the forming groove. You can also. In this case, the presence of the hardened layer can improve the wear resistance of the molding groove,
The life of the honeycomb structure forming mold can be extended.

[0028]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment A die for forming a honeycomb structure, a method for manufacturing the same, and a groove processing apparatus according to an embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 2, the honeycomb structure forming die 1 manufactured in this example includes a supply hole 2 for supplying a material, a lattice-shaped forming groove 4 for forming a material into a honeycomb shape, and a And a lower groove 3 disposed between the supply hole 2 and the shape of the forming groove 4.

The lower groove 3 has a cross-sectional area of a groove that is at least 2.5 times wider than the cross-sectional area of the forming groove 4. The forming groove 4 is processed by irradiation with a high-density energy beam and has an inner wall. Are formed with vertical streaks (not shown). The cross-sectional shape of the molding groove 4 is slightly,
The incident side of the high density energy beam has a narrow tapered shape.

In manufacturing the mold 1 for forming a honeycomb structure, as shown in FIG. 1A, first, a base plate 5 made of carbon steel (SKD-61) was prepared. As this size, a square having a side of 150 to 300 mm and a thickness of 10 to 30 mm is used. Then, the diameter is 0.3 to 1.5 mm from one surface (the back surface 52) of the base plate 5.
Is formed. The supply holes 2 are formed by a drill. The supply hole 2 is formed halfway in the thickness direction so as not to penetrate the surface side.

Next, as shown in FIG. 1B, a lower groove 3 having a wider groove width than the molding groove 4 to be obtained is formed from the other surface (surface: lower groove forming surface) 51 of the base plate 5. The lower groove 3 and the supply hole 2 communicate with each other in the thickness direction of the base plate 5. In this example, the formation of the lower groove 3 was performed by milling. This machining can be performed by another method such as electric discharge machining using a thin plate electrode or wire electric discharge machining.

Next, as shown in FIG. 1C, an upper plate 6 made of carbon steel is prepared. As the size, a size smaller than the base plate 5 is used. For example, a square having a side of 50 to 200 mm or a diameter of 50 to 200 mm
And having a thickness of 1.0 to 5.0 mm can be used. Then, the upper plate 6 is joined to the lower groove forming surface 51 in which the lower groove 3 is opened in the base plate 5. This joining was performed by a copper brazing method. This joining can be performed by another joining method such as a thermal diffusion joining method.

Next, as shown in FIG.
The forming groove 4 is provided along the shape of. FIG. 3 shows a groove processing device 7 for forming the forming groove 4. As shown in the figure, the groove processing device 7 includes a beam irradiating means 71 for irradiating a high-density energy beam 9 so as to transmit from the surface of the upper plate 6 to the lower groove 3.
Moving means (not shown) for moving the beam irradiation means 74 along the lower groove 3; Gas supply means 72 for supplying the lower assist gas 81 to the irradiated portion of the high-density energy beam 4 from the lower groove 3 side opposite to the irradiated side and supplying the upper assist gas 82 from the irradiated side.
And

The beam irradiating means includes a radiation source (not shown)
, A high-density energy beam 9 composed of a laser beam (YAG laser) having a variable output is emitted, and can be adjusted to a desired beam diameter by a beam condensing lens 710. An upper nozzle 722 is provided around the condenser lens 710, and the upper nozzle 722 is configured to supply the upper assist gas 82 around the high-density energy beam 9. Further, the lower assist gas 81 is used for the lower nozzle 7.
21.

The lower nozzle 721 is provided with a coil spring 72
5 urges the base plate 5. The opening of the lower nozzle 721 is larger than the formation pitch of the supply holes 2, and is arranged so as to face at least one supply hole 2 regardless of the position.

The lower nozzle 721 and the upper nozzle 7
The gas supply means 72 provided with 22 is provided so as to be movable with the movement of the high-density energy beam 9 irradiated from the beam irradiation means 71. Specifically, the lower nozzle 7
21 and the upper nozzle 722 are provided coaxially with the beam irradiation means, and are provided so as to move in the left-right direction synchronously. Further, the groove processing device 7 is provided with a table 79 for fixing the base plate 5. The base plate 5 can be fixed by screwing a bolt 78 passing through the through hole 59 of the base plate 5 to the table 79.

In processing the above-mentioned groove by using the groove processing device 7, as shown in FIG. 3, a high-density energy beam 9 is irradiated in accordance with the output transmitted from the surface of the upper plate 6 to the lower groove 3. At the same time, the upper assist gas 8
2 while supplying the lower assist gas 81 and moving the beam irradiation means 71 and the gas supply means 72 relative to the upper plate 6 to advance the processing. Here, the output of the YAG laser as the high-density energy beam 9 is set to, for example, 45 W when the thickness of the upper plate 6 is 1.5 mm, so that a through groove is easily formed in the upper plate 6. be able to.

Further, the supply of the upper assist gas 82 from the upper nozzle 722 is performed while ensuring the flow of the upper assist gas 81 supplied from the lower nozzle 721 to the irradiation portion to the irradiation side. Specifically, in the case of this example, both upper and lower
By supplying at a pressure of kgf / cm ² , the lower assist gas 81 can be blown upward. This is because, as shown in FIG.
25, the lower assist gas 81 can be directly supplied to the irradiated portion via the supply hole 2 and the lower groove 3, whereas the lower assist gas 81 can be directly supplied through the supply hole 2 and the lower groove 3.
Since the upper nozzle 722 is arranged at a certain distance from the upper plate 6, the upper nozzle 722 is not blown so strongly as to prevent the lower assist gas 81 from blowing upward.

By supplying such assist gases 81 and 82, the melt 65 that has been melted by the irradiation of the high-density energy beam 9 is removed from the irradiation side of the high-density energy beam 9.
That is, it can be discharged and removed to the surface side of the upper plate 6.
Therefore, the groove processing by the high-density energy beam 9 can be performed without being affected by the residual of the melt 65 or the like, and a very accurate groove width can be obtained.
In addition, by utilizing the high productivity and the easy control of the high-density energy beam 6, it is possible to improve the productivity and reduce the manufacturing cost.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a method for manufacturing a honeycomb structure forming mold according to an embodiment.

FIG. 2 is a partially cutaway cross-sectional view of a mold for forming a honeycomb structure in the embodiment.

FIG. 3 is an explanatory view showing a groove processing device for forming grooves in the embodiment.

[Explanation of symbols]

 1. . . 1. die for forming a honeycomb structure, . . 2. supply holes, . . Lower groove, 4. . . Molding groove, 5. . . Base plate, 51. . . 5. lower groove forming surface; . . Upper plate, 65. . . Melt, 7. . . Groove processing device, 71. . . Beam irradiation means, 710. . . Condenser lens, 72. . . Gas supply means, 721. . . Lower nozzle, 722. . . Upper nozzle, 81. . . Lower assist gas, 82. . . 8. Upper assist gas, . . High density energy beam,

Claims (16)

[Claims] 1. A supply hole for supplying a material, a grid-shaped forming groove for forming a material into a honeycomb shape, and a supply hole provided along the shape of the forming groove. In a method for manufacturing a honeycomb structure forming die having a lower groove, the supply hole is formed from one surface of the base plate, and the lower groove having a groove width wider than the forming groove is formed from the other surface. The lower groove and the supply hole are communicated with each other in the thickness direction of the base plate, and then the upper plate is joined to the lower groove forming surface of the base plate where the lower groove is opened. A method for manufacturing a die for forming a honeycomb structure, comprising irradiating a high-density energy beam so as to transmit the lower groove and processing the forming groove. 2. The method for manufacturing a die for forming a honeycomb structure according to claim 1, wherein the cross-sectional area of the lower groove is 2.5 times or more the cross-sectional area of the lower groove. . 3. The processing of the forming groove according to claim 1, wherein an assist gas is supplied to an irradiated portion of the high-density energy beam from at least the lower groove side opposite to the irradiation side. A method for manufacturing a honeycomb structure forming mold, comprising: 4. The method according to claim 1, wherein:
Manufacturing a mold for forming a honeycomb structure, wherein the assist gas supplied from the lower groove side to the irradiation portion is also supplied from the irradiation side while ensuring the flow of the assist gas to the irradiation side. Method. 5. The method according to claim 1, wherein:
The supply of the assist gas from the lower groove side is performed using a movable nozzle, and the assist gas is supplied while moving the nozzle along with the movement of the high-density energy beam. A method for manufacturing a mold for forming a structure. 6. The method according to claim 1, wherein:
A shield plate having an opening around the high-density energy beam irradiation portion is arranged on the surface of the upper plate, and the shaping groove is processed while moving the shield plate along with the movement of the high-density energy beam. A method for manufacturing a die for forming a honeycomb structure, comprising: 7. The method according to claim 1, wherein:
A method for manufacturing a die for forming a honeycomb structure, comprising: after forming the lower groove, applying an adhesion inhibitor for preventing adhesion of a molten material to an inner wall of the lower groove. 8. A supply hole for supplying a material, a lattice-shaped forming groove for forming the material into a honeycomb shape, and a supply hole provided along the shape of the forming groove. An apparatus for processing said forming groove of a honeycomb structure forming die having a lower groove, wherein said supply hole and said lower groove are formed in advance, and said upper surface for forming said forming groove is formed on a surface side of said lower groove. Beam irradiating means for irradiating a high density energy beam to the mold material having a plate from the surface of the upper plate to the lower groove, and moving the beam irradiating means along the lower groove And a gas supply means for supplying an assist gas from at least the lower groove side opposite to the irradiation side of the high-density energy beam irradiation part with respect to the high-density energy beam irradiation part. Grooving equipment. 9. A groove processing apparatus for a die for forming a honeycomb structure according to claim 8, wherein a beam diameter and an output of the high-density energy beam emitted from said beam irradiation means are provided so as to be changeable. . 10. The gas supply means according to claim 8, wherein the gas supply means secures a flow of the assist gas supplied from the lower groove side to the irradiation portion toward the irradiation side, and also assists the assist gas from the irradiation side. A groove forming apparatus for a honeycomb structure forming die, wherein the groove forming apparatus is configured to supply the groove. 11. The gas supply means according to claim 8, wherein the gas supply means has a movable nozzle for supplying an assist gas from the lower groove side. A groove processing apparatus for a die for forming a honeycomb structure, wherein the groove processing apparatus is provided so as to be movable in accordance with movement of a density energy beam. 12. A groove processing apparatus for a die for forming a honeycomb structure according to claim 11, wherein said nozzle is provided coaxially with said beam irradiation means. 13. The high-density energy beam irradiating portion is provided on the surface of the upper plate with a shielding plate having an opening around the surface of the upper plate. A groove processing apparatus for a die for forming a honeycomb structure, wherein the processing of the forming groove is performed while moving along with the movement of the energy beam. 14. A supply hole for supplying a material, a lattice-shaped forming groove for forming a material into a honeycomb shape, and a supply hole provided along the shape of the forming groove. In the die for forming a honeycomb structure having a lower groove, the lower groove has a cross-sectional area of a groove that is at least 2.5 times wider than a cross-sectional area of the groove of the forming groove, and the forming groove has a high-density energy beam. A honeycomb structure forming die having a vertical line as a processing line formed on an inner wall thereof. 15. The mold for forming a honeycomb structure according to claim 14, wherein the cross-sectional shape of the forming groove has a narrow taper shape on the incident side of the high-density energy beam. 16. The molding groove forming portion according to claim 14, wherein the molding groove forming portion is made of carbon steel, and a hardened layer which is rapidly solidified after melting is formed on an inner wall of the molding groove. A mold for forming a honeycomb structure.