JP3820894B2 - Manufacturing method of mold for forming honeycomb structure - Google Patents

Description

[0001]
【Technical field】
The present invention relates to a method for manufacturing a mold for forming a honeycomb structure having lattice-shaped slit grooves.
[0002]
[Prior art]
In order to manufacture a ceramic honeycomb structure having hexagonal cells, it is necessary to perform extrusion molding using a mold having slit grooves in a hexagonal lattice shape. As shown in FIG. 2, which will be described later, the mold includes a honeycomb structure forming mold having a supply hole 81 for material supply and slit grooves 82 provided in a hexagonal lattice shape in communication with the supply hole 81. 8 is used.
[0003]
In order to form the hexagonal lattice slit grooves of the honeycomb structure forming mold 8, electric discharge machining is applied to the groove forming surface of the mold material.
As a conventional electric discharge machining electrode, an electric discharge machining electrode having a lattice shape corresponding to the shape of the entire slit groove to be obtained has been used. However, an improvement in the electrical discharge machining method is desired due to problems in the production cost, production days, and quality of the electrical discharge machining electrode itself.
[0004]
As an improvement measure, Japanese Patent Laid-Open No. 12-24840 discloses a method of performing electric discharge machining n times using an electric discharge machining electrode having a machining surface having a size obtained by dividing a groove forming surface into n regions in the width direction. Proposed. According to this method, a significant improvement effect can be obtained as compared with the conventional case of using a large electric discharge machining electrode that covers the entire slit groove.
[0005]
[Problems to be solved]
However, the following problems still remain in the above improvement measures. That is, when a honeycomb structure forming die having a groove forming surface with a circular overall shape is subjected to electric discharge machining, the dimension in the direction perpendicular to the dividing direction of the region obtained by dividing the groove forming surface in the width direction is It differs greatly at the end. When electric discharge machining is performed using one kind of electrode that is large enough to machine the central area, most of the machined surface is used in electric discharge machining in the central area, but when the edge is electric discharge machined. Is wasteful because only a part of the machined surface is used. In addition, even if the lattice dimensions of the slit grooves to be obtained are the same, if the outer diameter changes, it is necessary to change the maximum width of the electrode for electric discharge machining according to the dimensions.
[0006]
The present invention has been made in view of such conventional problems, and an object of the present invention is to provide a method for manufacturing a die for forming a honeycomb structure capable of more effectively using an electrode for electric discharge machining at the time of electric discharge machining of a slit groove. Is.
[0007]
[Means for solving problems]
The invention according to claim 1 is a honeycomb structure having at least a plurality of supply holes for material supply, and a slit groove provided in a hexagonal lattice shape in communication with the supply holes and for forming the material into a honeycomb shape. In a method of manufacturing a body molding die,
When machining the slit groove, it has a machined surface with an outer dimension smaller than the groove-forming surface of the mold material, and the machined surface is formed by connecting hexagonal grid-like electrodes, including its contour part. All of the electrodes are hexagonal grid-like, and the contour shape of the entire processed surface is a hexagonal shape in which each side is a concavo-convex shape along the grid shape of the hexagonal grid-shaped electrode. In the method for manufacturing a honeycomb structure forming die, the groove forming surface is subjected to electric discharge machining a plurality of times using an electric discharge machining electrode protruding from the periphery.
[0008]
Next, the effects of the present invention will be described.
In the present invention, the electric discharge machining electrode has an outer dimension smaller than the groove forming surface of the mold material, the contour shape is substantially polygonal, and the entire machining surface protrudes from the periphery. An electrode for electric discharge machining is used.
First, since the entire machining surface of the electrode for electric discharge machining protrudes from the periphery, electric discharge machining using the electrode for electric discharge machining can be performed without any restriction on any position on the groove forming surface. That is, even when only the central portion of the groove forming surface is processed, the periphery of the processing surface of the electric discharge machining electrode does not come into contact with the groove forming surface to prevent the processing surface from moving forward. Further, even if the machining surface is brought into contact with the outer peripheral edge of the groove forming surface, the electric discharge machining can be advanced without any limitation.
[0009]
Then, the groove forming surface of the mold material is divided into regions that are the same as or smaller than the contour shape of the processed surface, and each is subjected to electric discharge machining. At this time, the entire processed surface can be used literally for the same region as the contour shape of the processed surface. On the other hand, for example, when a region straddling the end of the groove forming surface is processed, a part of the processed surface is not used. Even in this case, when machining other parts, for example, the vicinity of the opposite end, the above-described machining surface that has not been used can be used. In addition, it is possible to conveniently set the above-mentioned area division. Therefore, as a result, the entire machining surface of the electric discharge machining electrode can be used efficiently on average.
[0010]
Moreover, if the lattice shape of the slit grooves in the honeycomb structure forming die to be processed is the same, the same electric discharge machining electrode can be used even if the overall size changes.
As described above, in the present invention, by using the electric discharge machining electrode having the machining surface having the above-described configuration, it is possible to promote the rationalization of electric discharge machining when manufacturing the honeycomb structure forming mold.
[0011]
Next , the contour shape of the processed surface of the electric discharge machining electrode is a substantially hexagonal shape. That is, the contour shape of the entire processed surface has a hexagonal shape in which each side is an uneven shape along the grid shape of the hexagonal grid electrode. Thereby, each process area | region on a groove | channel formation surface can be set efficiently and easily, without overlapping. Furthermore, when the circular groove forming surface is processed, the ratio of the unused portion of the processed surface can be reduced also at the end portion.
[0012]
Further, as in the second aspect of the invention, a plurality of places can be simultaneously subjected to electric discharge machining by using a plurality of the electric discharge machining electrodes simultaneously. In this case, since a plurality of locations can be subjected to electric discharge machining at the same time, the machining time for the entire portion can be shortened, and the electric discharge machining process can be further rationalized.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1
A method for manufacturing a mold for forming a honeycomb structure according to an embodiment of the present invention will be described with reference to FIGS.
In this example, as shown in FIGS. 1 and 2, at least a plurality of supply holes 81 for material supply and a hexagonal lattice shape communicating with the supply holes 81 to form the material into a honeycomb shape are provided. The honeycomb structure forming mold 8 having the slit grooves 82 is manufactured.
When processing the slit groove 82, as shown in FIGS. 4 and 5, the slit groove 82 has a processing surface 10 having an outer dimension smaller than the groove forming surface 85 of the mold material 80, and the contour shape of the processing surface 10 is substantially the same. The groove forming surface 85 is subjected to electric discharge machining a plurality of times by using the electric discharge machining electrode 1 which is polygonal and protrudes from the surrounding substrate portion 18 as a whole.
[0014]
This will be described in detail below.
In manufacturing the honeycomb structure forming mold 8 to be manufactured in this example, first, as shown in FIG. 3A, a mold material 80 having a groove forming surface 85 and a hole forming surface 84 on the front and back is prepared. To do.
Next, as shown in FIG. 3B, a large number of supply holes 81 are provided in the hole forming surface 84 of the mold material 80 by drilling.
Thereafter, as shown in FIG. 2 and FIG. 3C, hexagonal lattice slit grooves 82 are formed by electric discharge machining. Thereby, as shown in FIGS. 1A and 1B, the honeycomb structure molding die 8 having a large number of hexagonal lattice slit grooves 82 on the groove forming surface 85 protruding from the peripheral portion 88 is obtained.
[0015]
In the electric discharge machining, as shown in FIGS. 4 and 5, a small electric discharge machining electrode 1 having a machining surface 10 whose outer dimensions are smaller than the groove forming surface 85 of the mold material 80 is used. In this example, as shown in FIG. 5, the maximum diameter L of the processed surface 10 is sufficiently smaller than the width (diameter) R of the groove forming surface 85 of the mold material 80 and is 1/5 or less.
Further, the machining surface 10 has a substantially hexagonal outline. Specifically, each side of the hexagon has an uneven shape along the lattice shape, but the overall shape is a hexagon.
[0016]
Further, as shown in FIG. 5, the processed surface 10 is composed of a hexagonal grid-like electrode 15 that is entirely protruded by a height H10 mm from the surrounding substrate 18 and includes its contour portion. Thus, all of the electrodes 15 can be processed.
Further, the inside of the hexagonal lattice of the machining surface 10 in the electric discharge machining electrode 1 is provided so as to penetrate to the back surface. In addition, a hexagonal through hole 17 is provided in the substrate portion 18 around the processed surface 10. This is a hole used when forming the processed surface 10. As shown in FIG. 4, the round holes 161 and 162 provided in the substrate portion 18 are holes for inserting a fixture for fixing the electric discharge machining electrode 1 to the electric discharge machining apparatus.
[0017]
Next, when machining the die material 80 using the electric discharge machining electrode 1, an electric discharge machining device 5 as shown in FIG. 6 is used. The electric discharge machining device 5 includes a base portion 51 disposed in a tank 50 and a suction device 52 built in the base portion 51, and is configured to set a mold material 80 on the upper surface of the suction device 52. Further, an electric discharge machining electrode 1 is fixed to a head (not shown) above the mold material 80 and supported so as to be movable up and down and left and right. In addition, a voltage is applied between the electric discharge machining electrode 1 and the mold material 80 by a power supply 55. Further, the working liquid 59 is filled in the tank 50 so that the lower part is sufficiently immersed below the electric discharge machining electrode 1.
[0018]
In actual processing, first, as shown in FIG. 7, 19 regions S1 to S19 having a hexagonal shape are assumed. Then, using the electric discharge machining electrode 1, these regions S <b> 1 to S <b> 19 are subjected to electric discharge machining in the order of the subscript numbers attached to S.
Specifically, first, the central region S1 is subjected to electric discharge machining. Next, the peripheral regions S2 to S7 are sequentially subjected to electric discharge machining. The electric discharge machining of these regions S1 to S7 is performed using the entire machining surface 10 of the electric discharge machining electrode 1. For this reason, the electric discharge machining electrode 1 is effectively used without waste up to this point.
[0019]
Next, in this example, the region S8 is subjected to electric discharge machining. At this time, only the left half of the processed surface 10 is used, and the right half is unused. Next, a region S9 located point-symmetrically with the region S8 with respect to the center of the groove forming surface 85 is subjected to electric discharge machining. At this time, only the right half of the processed surface 10 is used, and the left half is unused. Therefore, by processing these two areas S8 and S9, the entire processed surface 10 is used on average.
[0020]
Next, the regions S10, S11,. . . . By sequentially performing electrical discharge machining with S19, a pair of symmetric regions with respect to the center of the groove forming surface 85 are sequentially subjected to electrical discharge machining. Thereby, the processing surface 10 which was not used at the time of one process of a pair of object area | region is used when processing the other object area | region reliably. Therefore, the processed surface 10 is used on an average without much deviation.
[0021]
Thus, in this example, the entire machining surface 10 can literally be used without waste for the regions S1 to S7 having the same size as the machining surface 10 during electric discharge machining. On the other hand, when a region near the end of the groove forming surface 85 is processed, a part of the processed surface 10 may not be used. However, as described above, it is possible to effectively use a portion that has not been used previously at the time of machining a plurality of other locations. Therefore, as a result, the entire machining surface 10 of the electric discharge machining electrode 1 can be used efficiently on average.
[0022]
Further, in this example, as described above, the contour shape of the machining surface 10 of the electric discharge machining electrode 1 is substantially hexagonal. Thereby, each process area | region S1-S19 on the groove | channel formation surface 85 was able to be set efficiently and easily, without overlapping. Further, when the circular groove forming surface 85 is processed, the ratio of the unused portion of the processed surface can be reduced also at the end portion.
However, it is possible to change the contour shape to other polygonal shapes such as a substantially square shape instead of the hexagonal shape.
[0023]
If the dimension of the hexagonal lattice is the same even if the outer diameter R of the groove forming surface 85 of the mold material 8 changes, the electric discharge machining electrode 1 having the same machining surface 10 as described above is used. , EDM can be performed in the same procedure as above. Therefore, the electric discharge machining electrode 1 can be used more effectively.
[0024]
Embodiment 2
This example is an example in which a plurality of portions for electric discharge machining in Embodiment Example 1 are simultaneously used, and a plurality of places are subjected to electric discharge machining simultaneously.
Specifically, as shown in FIG. 7, the groove forming surface 85 is divided into 19 regions as in the first embodiment, and these are classified into five groups G1 to G5. The machining surfaces 10 of the seven electric discharge machining electrodes 1 were set on the head of the electric discharge machining apparatus 5 similar to the above so as to correspond to the region of the group G1, and the electric discharge machining was repeated.
[0025]
First, the seven regions of the group G1 are subjected to electric discharge machining, and then the seven electric discharge machining electrodes 1 are moved in a state where their relative positions are not changed, and the five regions of the group G2 are subjected to electric discharge machining. Further, the electric discharge machining electrode 1 is moved to perform electric discharge machining on the five regions of the group G3. Thereafter, one region of the group G4 is subjected to electric discharge machining, and finally one region of the group G5 is subjected to electric discharge machining.
Thus, in this example, 19 regions can be subjected to electric discharge machining in 5 cycles. Thereby, the whole electric discharge machining time can be shortened compared with the case of the first embodiment.
[0026]
Embodiment 3
In this example, another example of the shape of the machining surface 10 of the electric discharge machining electrode 1 used in the first embodiment is shown.
FIG. 9 has the same pattern as in the first embodiment. That is, each hexagon is completely formed in the contour portion of the processed surface 10, and there are irregularities along the shape, and the hexagon is formed as a whole.
[0027]
On the other hand, FIG. 10 has a unit cell similar to the above, but the arrangement direction is changed. And in the outline part of the processing surface 10, it has a shape which cut | disconnected the hexagon in half.
Even if it is any pattern, the effect similar to Example 1 can be acquired.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory view showing (a) the overall shape and (b) a slit groove forming state of a honeycomb structure forming mold in Embodiment 1;
2A is a partially cutaway perspective view of a groove forming surface of a honeycomb structure forming mold in Embodiment 1 and a supply hole, and FIG. 2B is an explanatory view viewed from the front.
3 is an explanatory view showing a manufacturing process of a honeycomb structure forming mold in Embodiment 1; FIG.
4 is a perspective view showing an electric discharge machining electrode in Embodiment 1. FIG.
5 is a partially enlarged perspective view of an electric discharge machining electrode in Embodiment 1. FIG.
6 is an explanatory diagram showing a configuration of an electric discharge machining electrode in Embodiment 1. FIG.
7 is an explanatory diagram showing an electric discharge machining area on a groove forming surface in Embodiment 1. FIG.
FIG. 8 is an explanatory view showing an electric discharge machining region on a groove forming surface in Embodiment 2.
FIG. 9 is an explanatory view showing a machined surface pattern of an electric discharge machining electrode in Embodiment 3;
10 is an explanatory view showing another machining surface pattern of an electrode for electric discharge machining in Embodiment 3. FIG.
[Explanation of symbols]
1. . . Electrodes for electrical discharge machining,
10. . . Machined surface,
15. . . electrode,
18. . . Substrate section,
8). . . Mold for forming honeycomb structure,
80. . . Mold material,
81. . . Supply holes,
82. . . Slit groove,
85. . . Groove forming surface,

Claims (2)

Manufactures a honeycomb structure molding die having at least a plurality of supply holes for material supply, and a hexagonal grid connected to the supply holes, and slit grooves for forming the material into a honeycomb shape In the way to
When machining the slit groove, it has a machined surface with an outer dimension smaller than the groove-forming surface of the mold material, and the machined surface is formed by connecting hexagonal grid-like electrodes, including its contour part. All of the electrodes are hexagonal grid-like, and the contour shape of the entire processed surface is a hexagonal shape in which each side is a concavo-convex shape along the grid shape of the hexagonal grid-shaped electrode. A method for manufacturing a die for forming a honeycomb structure, wherein the groove forming surface is subjected to electric discharge machining a plurality of times using an electric discharge machining electrode protruding from the periphery. 2. The method for manufacturing a honeycomb structure molding die according to claim 1, wherein a plurality of the electric discharge machining electrodes are simultaneously used, and a plurality of locations are subjected to electric discharge machining simultaneously.

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