JP3400839B2 - Wire discharge cutting method for metal catalyst carrier - Google Patents
Wire discharge cutting method for metal catalyst carrierInfo
- Publication number
- JP3400839B2 JP3400839B2 JP00116394A JP116394A JP3400839B2 JP 3400839 B2 JP3400839 B2 JP 3400839B2 JP 00116394 A JP00116394 A JP 00116394A JP 116394 A JP116394 A JP 116394A JP 3400839 B2 JP3400839 B2 JP 3400839B2
- Authority
- JP
- Japan
- Prior art keywords
- discharge
- metal
- wire
- cutting
- current value
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Description
【発明の詳細な説明】
【０００１】
【産業上の利用分野】本発明は、自動車排ガス浄化装置
など、内燃機関の排気処理装置に使用される金属製のハ
ニカム体、あるいはこれを金属製の外筒に嵌合させたメ
タル担体（本明細書において金属製触媒担体はこれらを
総称したものである）をワイヤ放電切断法により切断す
る方法に関するものである。
【０００２】
【従来の技術】自動車エンジンなどの内燃機関から排出
されるガスには、ＣＯやＮＯｘなどの有害成分が含まれ
ており、これらを無害化するために、白金、パラジウム
などの触媒が使用される。触媒は、断面がハニカム状
で、各孔が長さ方向に貫通した円筒形状の金属製触媒担
体に担持されており、この担体に排ガスを通すことで処
理が行われる。
【０００３】金属製触媒担体は、通常、図３（ａ）に示
すように平板１１と波板１２を重ねて渦巻状に巻取り、
図３（ｂ）のような円筒状のハニカム体１３とし、図３
（ｃ）のように、容器としての機能と構造強度体として
の機能を併せ持つ外筒１４に嵌合させてメタル担体１５
としたものが使用される。メタル担体１５には、用途に
応じた各種寸法のものが製造されるが、ハニカム体１３
の直径、長さ、およびメッシュ寸法は、平板１１および
波板１２の長さと幅、および波板１２の波高と波幅によ
って決まり、これを所定寸法の外筒１４に嵌合させる。
【０００４】ところで、各種長さのメタル担体を製造す
るには、それに合わせた各種寸法の平板、波板および外
筒を準備する必要があり、また平板と波板を重ねて巻き
取る際には両エッジを揃えて巻くための位置決め等のた
め、作業性が劣るという問題があった。そこで、長尺の
ハニカム体あるいはメタル担体を切断して複数の金属製
触媒担体を製造することが考えられたが、鋸断等により
機械的に切断すると、ハニカム体を構成している１００
μｍ以下の平板および波板にバリやだれが発生し、排ガ
ス処理用の触媒担体としての機能性が損なわれる。
【０００５】従来、加工歪みを生じることなく切断する
方法として、ワイヤ放電切断法が知られている。この方
法は、無歪の精密加工が行えるものの、加工速度が遅い
という欠点があったが、近年、加工速度の律速であった
ワイヤ断線を防止する技術が進歩したことにより、放電
エネルギーを大きくして加工速度を高めることができる
ようになり、各種部品の切断加工への適用が可能になっ
た。
【０００６】
【発明が解決しようとする課題】本発明者は、図３のよ
うな各種のハニカム体やメタル担体を、ワイヤ放電切断
法により切断した結果、バリやだれが発生することなく
切断できるが、実用的な速度で切断できるように放電エ
ネルギーを高めると、ハニカム状にした金属平板あるい
は金属波板に亀裂が発生した。
【０００７】本発明は、自動車排ガス浄化装置等に使用
される金属製触媒担体の製造において、ハニカム体ある
いはメタル担体という特殊な材料の切断にワイヤ放電切
断法を適用して、切断面に損傷を与えることなく実用的
な速度で切断することにより、生産性および製造歩留ま
りを向上させることを目的とする。
【０００８】
【課題を解決するための手段】上記目的を達成するため
の本発明は、厚さ１００μｍ以下の金属波板と金属平板
を渦巻状に巻回して円筒状に形成したハニカム体、また
は該ハニカム体を金属製の外筒に嵌合させたメタル担体
を、ワイヤ放電切断法で切断する方法において、１発の
放電波形における電流値を、切断時にハニカム体の平板
と波板に亀裂が発生しない上限の電流値に設定し、次に
この電流値を固定した状態で放電エネルギーがワイヤ断
線の生じない上限となるような放電時間に設定すること
を特徴とする金属製触媒担体のワイヤ放電切断方法であ
る。
【０００９】
【作用】本発明法の対象とするワイヤ放電切断法の例を
図１に示す。金属製触媒担体１（図３のようなハニカム
体１３あるいはメタル担体１５を総称したもの）に、ワ
イヤ２を走行させつつ、水中で両者間に放電させ、糸鋸
式に切断する。金属製触媒担体１は担体保持具７で保持
され、図示しないサーボ機構により矢印の方向に送られ
る。ワイヤ２は、供給リール３からブレーキ４および巻
取ローラー５を経て巻取リール６に巻き取られ、ブレー
キ４と巻取ローラー５の間で、直線状に張られた状態で
金属製触媒担体１に当接する。ワイヤ２と担体保持具７
の間に、加工電源８からパルス電流９を供給し、水中に
て両者間で放電させる。
【００１０】ワイヤ２としては、黄銅、タングステン、
モリブデン等の細線が使用される。水は脱イオン水が用
いられ、放電が生じやすいように電導度が管理される。
被加工部への水の供給は、ノズルにより行うこともでき
るが、本発明においては、被加工材の断面がハニカム状
であるため、加工部を水中に浸漬して行うのが好まし
い。
【００１１】本発明法はこのようなワイヤ放電切断法に
おいて、図２のような１発の放電波形における電流値ｉ
および放電時間τを、それぞれ独立に変化させて、適正
値に設定するものである。本発明の対象とする金属製触
媒担体は、図３に示したような特殊の形態をしており、
ワイヤ放電切断法によって切断するとき、単に放電エネ
ルギーを高めて切断速度を上げると、厚さが１００μｍ
以下の薄い平板および波板に亀裂が発生した。
【００１２】従来のワイヤ放電切断法について、本発明
者が検討しところ、放電の電流値と放電時間は一体的に
変化するようになっていた。すなわち、１発の放電波形
についてみると、図２（ｂ）のように、電流値ｉ0 ，放
電時間τ0 の放電波形から電流値をｉ2 に高めると、放
電時間がτ2 へと、放電波形が相似形の状態で変化する
ように設計されていた。つまり従来のワイヤ放電切断法
では、切断能力は放電エネルギー（ｉ×τに比例）に関
係することから、電流値と放電時間を一体的に調整する
方法が採用されていた。
【００１３】しかし、本発明の対象とする金属製触媒担
体を切断するときは、このような考え方で切断速度を上
げるために放電エネルギーを高めると、上記のように亀
裂が発生するという問題が生じた。本発明者が、１発の
放電波形について電流値ｉおよび放電時間τをそれぞれ
独立に変化させて切断した結果、厚さが１００μｍ以下
の薄い平板および波板に発生する亀裂の大きさおよび発
生頻度は電流値ｉに影響されることが判明した。
【００１４】そこで、切断に際して、図２（ａ）のよう
に、まず電流値ｉを亀裂が発生しない上限の電流値ｉ1
に設定する。この電流値は、切断対象の金属製触媒担体
を構成する平板および波板の厚さ、ハニカムのサイズ、
各板の成分、担体の径などにより変化するので、対象材
が変わったときは、それに応じて適正値に調整する。つ
ぎに、電流値をｉ1 に固定した状態で放電時間τを調整
し、放電エネルギーがワイヤ断線を生じない上限となる
ような放電時間τ1 に設定する。そして放電間隔（放電
周期）をワイヤ断線の生じない下限になるように設定す
る。
【００１５】このような本発明法によれば、断面がハニ
カム状をなす特殊な形状の金属材料をワイヤ放電切断法
で、材料に損傷を与えることなく、実用的な速度で切断
することができる。
【００１６】
【実施例】フェライト系ステンレス鋼製の厚さ０．０５
mmの平板および波板を重ねて渦巻状に巻回したハニカム
体を、同じくフェライト径ステンレス鋼製の外筒に嵌合
させたメタル担体について、脱イオン水に浸漬して行っ
た実施例を表１に示す。なお、表１において電流値、放
電時間および放電周期は、いずれも従来例を１とする
比で示している。
【００１７】従来例では、電流値と放電時間をそれぞれ
独立に変化させて設定することができず、実用的な時間
５．５分で切断した従来例では、担体を構成する平板
および波板に多数の亀裂が発生した。亀裂が発生しない
ように放電エネルギーを低下させた従来例では、切断
に長時間を要した。
【００１８】これに対し本発明例では、電流値を従来
例の８０％に、放電時間を１３０％にして、亀裂を発
生させず実用的な５．５分で切断できた。本発明例
は、より大径の担体を同条件で切断したもの、本発明
例は、と同一の電流値で放電時間をやや延長したも
のである。いずれも亀裂発生なく良好な断面が得られ
た。この結果、担体の径が大きくなる場合には、電流値
は変えず、放電時間を長くして被切断材中で損失する放
電エネルギーを補うことにより、亀裂を発生させること
なく切断時間の大幅延長が抑制されることが判明した。
なお、本発明例において、放電時間をこれより長くす
るとワイヤ断線が生じたことから、放電時間の上限は、
ワイヤ断線の有無に基づいて設定する。
【００１９】
【表１】
【００２０】
【発明の効果】本発明法によれば、図３に示すような金
属製のハニカム体１３あるいはメタル担体をワイヤ放電
切断法により、切断面の損傷なく実用的な速度で切断で
きる。ワイヤ放電切断は自動化が可能であり、また１本
の材料を複数箇所で同時に切断することもでき、自動車
排ガス浄化装置等に使用される金属製触媒担体の製造に
おいて、生産性および製造歩留まりの向上が達成でき
る。Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal honeycomb body used for an exhaust treatment device of an internal combustion engine such as an automobile exhaust gas purification device, or a metal honeycomb body. The present invention relates to a method for cutting a metal carrier fitted in a cylinder (in the present specification, a metal catalyst carrier is a generic name for these) by a wire discharge cutting method. [0002] Gas exhausted from an internal combustion engine such as an automobile engine contains harmful components such as CO and NOx, and a catalyst such as platinum or palladium is used to detoxify these components. used. The catalyst is supported on a cylindrical metal catalyst carrier having a honeycomb cross section and each hole penetrating in the length direction, and the exhaust gas is passed through the carrier to perform the treatment. As shown in FIG. 3 (a), a metal catalyst carrier is usually formed by stacking a flat plate 11 and a corrugated plate 12 and spirally winding them.
As shown in FIG. 3B, a cylindrical honeycomb body 13 as shown in FIG.
As shown in (c), the metal carrier 15 is fitted to the outer cylinder 14 having both the function as a container and the function as a structural strength body.
Is used. The metal carrier 15 is manufactured in various sizes depending on the application.
Is determined by the length and width of the flat plate 11 and the corrugated plate 12, the wave height and the wave width of the corrugated plate 12, and these are fitted to the outer cylinder 14 having a predetermined size. [0004] In order to manufacture metal carriers of various lengths, it is necessary to prepare flat plates, corrugated plates and outer cylinders of various dimensions corresponding to the lengths. There is a problem that workability is inferior due to positioning or the like for winding both edges together. Therefore, it has been considered that a plurality of metal catalyst carriers are manufactured by cutting a long honeycomb body or a metal carrier. However, when the honeycomb body is mechanically cut by sawing or the like, a honeycomb body is formed.
Burrs and drooling occur on flat plates and corrugated plates of μm or less, and the function as a catalyst carrier for exhaust gas treatment is impaired. Conventionally, a wire discharge cutting method has been known as a method for cutting without generating machining distortion. Although this method can perform distortion-free precision machining, it has a disadvantage that the machining speed is slow.However, in recent years, the technology for preventing wire breakage, which was the rate-limiting of the machining speed, has increased discharge energy. It has become possible to increase the processing speed and to apply it to cutting of various parts. SUMMARY OF THE INVENTION The present inventor can cut various honeycomb bodies and metal carriers as shown in FIG. 3 by a wire discharge cutting method, and as a result, do not generate burrs or dripping. However, when the discharge energy was increased to enable cutting at a practical speed, cracks occurred in the honeycomb-shaped metal flat plate or metal corrugated plate. According to the present invention, in the production of a metal catalyst carrier used for an automobile exhaust gas purifying apparatus or the like, a wire discharge cutting method is applied to the cutting of a special material such as a honeycomb body or a metal carrier, so that the cut surface is damaged. It is an object to improve productivity and production yield by cutting at a practical speed without giving. [0008] In order to achieve the above object, the present invention provides a honeycomb body in which a metal corrugated sheet and a metal flat sheet having a thickness of 100 µm or less are spirally wound to form a cylindrical body, or In a method of cutting a metal carrier in which the honeycomb body is fitted into a metal outer cylinder by a wire discharge cutting method, a current value in one discharge waveform is determined by cutting a flat plate of the honeycomb body at the time of cutting.
Metal, characterized in that it is set to the upper limit of the current value at which cracks do not occur in the corrugated sheet, and then the discharge time is set so that the discharge energy becomes the upper limit at which the wire break does not occur with this current value fixed. This is a method for wire discharge cutting of a catalyst carrier. FIG. 1 shows an example of the wire discharge cutting method to which the present invention is applied. While the wire 2 is running on the metal catalyst carrier 1 (which collectively refers to the honeycomb body 13 or the metal carrier 15 as shown in FIG. 3), the wire 2 is discharged between the two in water and cut in a jigsaw manner. The metal catalyst carrier 1 is held by a carrier holder 7 and sent in the direction of the arrow by a servo mechanism (not shown). The wire 2 is taken up from a supply reel 3 to a take-up reel 6 via a brake 4 and a take-up roller 5, and is linearly stretched between the brake 4 and the take-up roller 5 in a state where the metal catalyst carrier 1 is stretched. Abut. Wire 2 and carrier holder 7
During this time, a pulse current 9 is supplied from the machining power supply 8 to discharge between the two in water. As the wire 2, brass, tungsten,
A thin wire such as molybdenum is used. As the water, deionized water is used, and the conductivity is controlled so that electric discharge easily occurs.
Although the supply of water to the workpiece can be performed by a nozzle, in the present invention, the workpiece is preferably immersed in water because the cross section of the workpiece is a honeycomb shape. According to the method of the present invention, the current value i in one discharge waveform as shown in FIG.
And the discharge time τ are independently changed and set to appropriate values. The metal catalyst carrier to which the present invention is applied has a special form as shown in FIG.
When cutting by the wire discharge cutting method, simply increasing the discharge energy to increase the cutting speed results in a thickness of 100 μm.
Cracks occurred in the following thin flat plates and corrugated plates. The present inventor has studied the conventional wire discharge cutting method, and found that the discharge current value and the discharge time are integrally changed. That is, looking at one discharge waveform, as shown in FIG. 2B, when the current value is increased from the discharge waveform of the current value i 0 and the discharge time τ 0 to i 2 , the discharge time becomes τ 2 . The discharge waveform was designed to change in a similar manner. That is, in the conventional wire discharge cutting method, since the cutting ability is related to the discharge energy (proportional to i × τ), a method of integrally adjusting the current value and the discharge time has been adopted. However, when cutting the metal catalyst carrier, which is the object of the present invention, if the discharge energy is increased in order to increase the cutting speed based on the above concept, the problem that cracks occur as described above arises. Was. As a result of cutting by changing the current value i and the discharge time τ independently for one discharge waveform by the present inventor, the size and frequency of cracks generated in a thin flat plate and a corrugated plate having a thickness of 100 μm or less are obtained. Has been found to be affected by the current value i. Therefore, at the time of cutting, as shown in FIG. 2A, first, the current value i is changed to the upper limit current value i 1 at which no crack occurs.
Set to. This current value is the thickness of the flat plate and corrugated plate constituting the metal catalyst carrier to be cut, the size of the honeycomb,
Since it changes depending on the components of each plate, the diameter of the carrier, etc., when the target material changes, it is adjusted to an appropriate value accordingly. Next, the discharge time τ is adjusted in a state where the current value is fixed at i 1 , and the discharge time τ 1 is set so that the discharge energy becomes the upper limit at which the wire is not broken. Then, the discharge interval (discharge cycle) is set to a lower limit at which no wire breakage occurs. According to the method of the present invention, a metal material having a special shape having a honeycomb cross section can be cut by a wire discharge cutting method at a practical speed without damaging the material. . Example: Ferrite stainless steel with a thickness of 0.05
Table 1 shows an example in which a honeycomb body formed by spirally winding a flat plate and a corrugated plate with a thickness of mm on a metal carrier similarly fitted in an outer cylinder made of ferritic stainless steel was immersed in deionized water. It is shown in FIG. In Table 1, the current value, the discharge time, and the discharge cycle are all shown as ratios of the conventional example as 1. In the conventional example, the current value and the discharge time cannot be changed independently of each other, and the current value and the discharge time cannot be set independently. Numerous cracks occurred. In the conventional example in which the discharge energy was reduced so that cracks did not occur, it took a long time to cut. On the other hand, in the example of the present invention, the current value was set to 80% of that of the conventional example, and the discharge time was set to 130%. In the example of the present invention, a carrier having a larger diameter was cut under the same conditions, and in the example of the present invention, the discharge time was slightly extended at the same current value. In each case, good cross sections were obtained without crack generation. As a result, when the diameter of the carrier becomes large, the current value is not changed, and the discharge time is extended to compensate for the discharge energy lost in the material to be cut, so that the cutting time is greatly extended without generating a crack. Was found to be suppressed.
In the example of the present invention, if the discharge time is longer than this, wire breakage occurs, so the upper limit of the discharge time is:
Set based on the presence or absence of wire break. [Table 1] According to the method of the present invention, the metal honeycomb body 13 or the metal carrier as shown in FIG. 3 can be cut by a wire discharge cutting method at a practical speed without damaging the cut surface. Wire discharge cutting can be automated, and one piece of material can be cut simultaneously at multiple locations, improving productivity and production yield in the production of metal catalyst carriers used in automobile exhaust gas purification equipment and the like. Can be achieved.
【図面の簡単な説明】
【図１】本発明法の説明図である。
【図２】本発明法および従来法における１発の放電波形
を示す図である。
【図３】（ａ）本発明の対象とするハニカム体の巻取方
法を説明する斜視図である。
（ｂ）本発明の対象とするハニカム体の斜視図である。
（ｃ）本発明の対象とするメタル担体の斜視図である。
【符号の説明】
１：金属製触媒担体
２：ワイヤ
３：供給リール
４：ブレーキ
５：巻取ローラー
６：巻取リール
７：担体保持器
８：加工電源
９：パルス電流
１１：平板
１２：波板
１３：ハニカム体
１４：外筒
１５：メタル担体BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory diagram of the method of the present invention. FIG. 2 is a diagram showing one discharge waveform in the method of the present invention and the conventional method. FIG. 3 (a) is a perspective view illustrating a method of winding a honeycomb body according to the present invention. (B) It is a perspective view of the honeycomb object which is an object of the present invention. (C) A perspective view of the metal carrier to which the present invention is applied. [Description of Signs] 1: Metal catalyst carrier 2: Wire 3: Supply reel 4: Brake 5: Winding roller 6: Winding reel 7: Carrier holder 8: Processing power supply 9: Pulse current 11: Flat plate 12: Wave Plate 13: honeycomb body 14: outer cylinder 15: metal carrier
───────────────────────────────────────────────────── フロントページの続き (72)発明者 内海 徹 東京都千代田区大手町２−６−３ 新日 本製鐵株式会社内 (56)参考文献 特開 昭64−64723（ＪＰ，Ａ) 特開 昭61−125733（ＪＰ，Ａ) 特開 昭57−121424（ＪＰ，Ａ) 特開 昭62−287946（ＪＰ，Ａ) 特公 昭37−346（ＪＰ，Ｂ１) 特公 昭46−13707（ＪＰ，Ｂ１) (58)調査した分野(Int.Cl.7，ＤＢ名) B23H 7/02 B23H 1/02 B23H 9/00 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Toru Utsumi 2-6-3 Otemachi, Chiyoda-ku, Tokyo Inside Nippon Steel Corporation (56) References JP-A-64-64723 (JP, A) JP-A-61-125733 (JP, A) JP-A-57-121424 (JP, A) JP-A-62-287946 (JP, A) JP-B-37-346 (JP, B1) JP-B-46-13707 ( JP, B1) (58) Fields investigated (Int. Cl. 7 , DB name) B23H 7/02 B23H 1/02 B23H 9/00
Claims (1)
板を渦巻状に巻回して円筒状に形成したハニカム体、ま
たは該ハニカム体を金属製の外筒に嵌合させたメタル担
体を、ワイヤ放電切断法で切断する方法において、１発
の放電波形における電流値を、切断時にハニカム体の平
板と波板に亀裂が発生しない上限の電流値に設定し、次
にこの電流値を固定した状態で放電エネルギーがワイヤ
断線の生じない上限となるような放電時間に設定するこ
とを特徴とする金属製触媒担体のワイヤ放電切断方法。(57) [Claim 1] A honeycomb body formed by winding a metal corrugated sheet and a metal flat plate having a thickness of 100 µm or less in a spiral shape, or a metal outer cylinder made of the honeycomb body In the method in which the metal carrier fitted to the wire is cut by the wire discharge cutting method, the current value in one discharge waveform is determined by cutting the flat surface of the honeycomb body at the time of cutting.
It is characterized in that the current value is set to the upper limit at which cracks do not occur in the plate and the corrugated sheet, and then the discharge time is set so that the discharge energy becomes the upper limit at which wire breakage does not occur with this current value fixed. Wire discharge cutting method for metal catalyst carrier.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP00116394A JP3400839B2 (en) | 1994-01-11 | 1994-01-11 | Wire discharge cutting method for metal catalyst carrier |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP00116394A JP3400839B2 (en) | 1994-01-11 | 1994-01-11 | Wire discharge cutting method for metal catalyst carrier |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH07204938A JPH07204938A (en) | 1995-08-08 |
| JP3400839B2 true JP3400839B2 (en) | 2003-04-28 |
Family
ID=11493778
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP00116394A Expired - Fee Related JP3400839B2 (en) | 1994-01-11 | 1994-01-11 | Wire discharge cutting method for metal catalyst carrier |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3400839B2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102006026779A1 (en) * | 2006-06-07 | 2007-12-20 | Leinemann Gmbh & Co. Kg | Flame arrestor arrangement and method for introducing bores into a flame arrester arrangement |
| CN105014725B (en) * | 2015-08-13 | 2017-04-05 | 天津智通机器人有限公司 | A kind of two ends synchronous cutting device |
| CN114603221B (en) * | 2022-04-19 | 2023-09-26 | 中国航发动力股份有限公司 | Electric spark power supply device for repairing honeycomb part hole plugging and testing method |
-
1994
- 1994-01-11 JP JP00116394A patent/JP3400839B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH07204938A (en) | 1995-08-08 |
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