JPS5838084B2 - Manufacturing method for honeycomb molding dies - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a honeycomb molding die, which is used, for example, when molding a ceramic honeycomb body as a catalyst carrier for automobile exhaust gas purification. It was designed to improve the

Conventionally known honeycomb forming dies include a number of independent holes drilled on one side of the die, a honeycomb mold groove of a predetermined depth formed on the other side of the die, and a connection between the honeycomb forming groove and the above holes. There is a grooved structure with a honeycomb-shaped through groove located between the two to communicate with each other.

The above-mentioned honeycomb molding grooves and through grooves have a cross-sectional shape corresponding to the cross-sectional shape of the core part of the honeycomb body, and the above-mentioned independent openings are formed at the intersections and/or ridges of the honeycomb molding grooves and through grooves. It is now possible to communicate.

When using a honeycomb molding die with such a conventional structure, for example, ceramic material is supplied to a large number of independent openings, and once it accumulates in the through groove, the accumulated ceramic material is not squeezed and is not squeezed. It flows into the molding groove, and a nicum-shaped molded body is continuously extruded from this molding groove.

The honeycomb molding die having the above-described structure is generally manufactured as follows.

That is, a block is previously machined from a metal material using a general-purpose machine such as a lathe, and then a large number of independent holes are bored from one side of the block to the other using a drill press or the like.

Next, a honeycomb molding groove is machined from the other side of the block body to one side by electric discharge machining, etc., and finally, the outer peripheral surface of the block body is machined by electric discharge machining etc. in a direction perpendicular to the axis of the opening. A through groove is machined in the shape of two cams.

However, according to the above-mentioned die manufacturing method, as the diameter and width of the block body increase, the processing depth of the through-groove also increases, so in such a case, it is very difficult to process the through-groove. The machining time is also longer, and when the electric discharge machining method is used, the width of the through-groove at the beginning and end of machining is significantly different due to the wear and tear of the discharge electrode during electric discharge machining, resulting in poor dimensional accuracy. I have a problem.

Therefore, as mentioned above, conventional honeycomb molding dies cannot extrude plastic materials due to the deviation of the groove width dimension of the through groove.
- There is a partial difference in the supply ratio to the honeycomb mold groove, and as a result, cracks occur in the extruded honeycomb-shaped body during firing.

Therefore, in view of the above-mentioned points, the present inventor first filed a patent application filed in 1973.
As filed as No. 117626, a honeycomb-shaped through groove is machined from one side of the block body to the other side, and a metal plate is bonded to one side of the block body where the through groove is machined. By machining honeycomb molding grooves in this metal plate so as to communicate with the through grooves, we have created a honeycomb molding die that can be easily and quickly processed, and has a through groove with almost no deviation in width dimension. I have already suggested a way to get it.

In the present invention proposed this time, when employing the brazing method to join the block body and the metal plate among the above-mentioned methods, after forming a recess in advance on either the block body or the metal plate, The purpose of this is to obtain the effect of improving the strength of the brazed joint by brazing the two together.

Hereinafter, the present invention will be explained in detail with reference to embodiments shown in the drawings.

First, the structure of the honeycomb molding die will be explained.

In FIGS. 1 to 3, 1 is a honeycomb molding groove, and this molding groove 1 has a cross-sectional shape corresponding to the cross-sectional shape (for example, a square in this example) of the core part 9 of the honeycomb-shaped molded body 8 shown in FIG. It is provided on the metal plate 4b from the front surface 2 of the die toward the rear surface 3 of the die.

Reference numeral 5 denotes a honeycomb-shaped through groove, and this through groove 5 has approximately the same cross-sectional shape as the molding groove 1 described above, and has a dimension wider than the width dimension of the molding groove 1, so that it communicates with the molding groove 1. It is provided on the die body 4a.

Reference numeral 6 denotes a large number of mutually independent holes (circular holes), and these holes 6 are formed on the die rear surface 3 of the die main body 4a so as to communicate orthogonally to every other intersection of the through grooves 5 at the subsequent stage. A hole is drilled at a predetermined depth toward the front surface 2 of the die.

The molding groove 1 communicates with the through groove 5 at a position that overlaps with the through groove 5 at the rear stage of the through groove 5.

Reference numeral 7 denotes a joint between the die main body 4a and the metal plate 4b. In this embodiment, this joint 7 is joined by brazing, so it is a brazing material, and in this embodiment, it is a copper brazing material.

Note that phosphor bronze solder, silver solder, nickel solder, etc. may be used as the brazing material.

The die body 4a and the metal plate 4 are joined to each other at the joining part 7
b is made into an integral die by joining.

As is clear from FIGS. 1 to 3, the holes 6 drilled from the rear surface 3 of the die are each independently drilled in the die body 4a, so that the die body 4a becomes one member. Therefore, the through groove 5 formed by processing the die front surface 2 side of the die body 4a is also formed in a part of one member.

On the other hand, if the mold groove 1 is formed on the rear surface 3 of the die, the metal plates 4b will be disjointed according to the shape of the core part 9 of the honeycomb body 8 shown in FIG. The die body 4a and the metal plate 4b are bonded together in advance by brazing.

The present invention particularly relates to the shape of the joint part 7, and when the block body 4a' and the metal plate 4b are brazed to each other by plane contact, if the plane precision of the contact surface is poor, locally, In view of the fact that some parts may not be able to be joined by brazing, as shown in FIG.
The recess 4lb is formed in a shape corresponding to the plane of the unprocessed portion 41a surrounded by the through groove 5 of the flock body 4a.

By brazing the concave portion 41b of the metal plate 4b while fitting it into the unprocessed portion 41a of the block body 4a, for example, even if the plane accuracy of the metal plate 4b is poor, it is possible to easily fit into the gap between them. The filler fills with the brazing filler metal, making it possible to achieve a reliable close bond.

Next, the manufacturing method performed in this example will be described in detail.

In FIG. 6 showing the manufacturing method, 4a/ is a block body corresponding to the die body 4a in FIGS. 1 to 3, and is made of SKD4 (alloy tool steel), and 4b is a block body corresponding to the die body 4a in FIGS. The metal plate shown in the figure before forming grooves is made of SKD4.

The first step is the step of preparing the block body 4a' and the metal plate 4b described above as shown in FIGS. 6a and 6d.

In the second step, the sixth
As shown in Figure b, one surface 40a corresponds to the rear surface 3 side of the die.
′ to the other surface 41a/, for example, by drilling a hole 6.
to a specified depth.

In the third step, a through groove 5 is formed into a honeycomb shape to a predetermined depth by cutting and electrical discharge machining, as shown in FIG. and take shape.

At this stage, the through groove 5 has the shape of a groove on a plane, so there is no need for a special processing method such as drilling an irregularly shaped deep hole from the side of the die as in conventionally known methods. Machining can be easily performed using extremely common groove processing methods such as end mill milling, metal milling, electrical discharge machining, ultrasonic machining, or IC wafer dicing.

In the fourth step, as shown in FIG. 6e, a concave portion 4lb corresponding to the planar shape of the non-machined portion 41a formed between the through grooves 5 of the block body 4a' is formed in the metal plate 4b by electric discharge machining, ultrasonic machining, etc. It is formed by processing it to a predetermined depth.

At this stage, the electric discharge machining method was adopted in this embodiment, and the block body 4a' was used for one electrode, and the metal plate 4b was used as the workpiece.
It was possible to easily form a concave portion 4ib whose size was larger by the discharge gap than the planar shape of the non-machined portion 41a.

In the fifth step, a brazing material is attached to the four parts 41b formed on the metal plate 4b by a plating method, a coating method, or the like.

In this embodiment, a copper brazing material is used as the brazing material, and if the depth of the recess 4lb of the metal plate 4b is small, a plating method may be used, otherwise a coating method may be used. Needless to say, the amount of brazing material is appropriately selected based on the amount of brazing material calculated from the tensile strength after application, the brazing area, etc.

In the sixth step, as shown in FIG. 6f, the recess 4lb of the metal plate 4b is
are fitted into the unprocessed portion 41a of the block body 4a' and brazed to each other.

That is, since the copper brazing method was used in this example, it was carried out at 1080° C. using a vacuum furnace.

The brazing material previously attached to the recess 4lb of the metal plate 4b is melted, and the die body 4a and the metal plate 4b are tightly joined.

At this time, since the through groove 5 is formed in the overlapping surface of the die body 4a and the metal plate 4b, the molten brazing metal reaches the side wall of the through groove 5 due to its own surface tension, and the inner wall of the through groove 5. The brazing material is attached to the right-angled corner formed by the metal plate 4b and the metal plate 4b.

The brazing filler metal present in the corners is useful for extrusion molding of a nicum-shaped molded product in that it prevents the formation of harmful ceramic material pools in the corners, so no modification was made in this example. I used Zuko as is.

In the seventh step, the thickness of the metal plate 4b is polished to a predetermined size. After machining, as shown in Fig. 6g, the molded groove 1 is formed into a through groove 5.
It was formed by electrical discharge machining at a position that overlaps with the

In this embodiment, the electric discharge machining method is used as the method of machining the molded groove 1, but the machining method is not limited to this, and may also be cutting, ultrasonic machining, lapping, etching, or the like.

Note that after forming the molding groove 1, the entire structure is heat-treated to increase hardness.

During extrusion molding, the die having the through grooves 5 produced by the manufacturing method of this example is molded into a honeycomb shape as shown in FIG. After being joined in a shape that roughly corresponds to the core part 9 of the body 8, the honeycomb-shaped molded body 8 is extruded in the molding groove 1, so that it does not have the through-groove 5 that was conventionally used. The depth of the molding groove 1 in the extrusion direction may be smaller than that in an extrusion die using a die having a similar configuration.

For these reasons, when performing electrical discharge machining as a processing method for the molded groove 1 formed in the seventh step, for example, it is difficult to maintain the width dimension accuracy of the groove if the groove is deep. When the depth of the groove is shallow, dimensional accuracy can be easily controlled.

Next, another embodiment of the present invention will be described with reference to FIGS. 7 and 8.

The embodiment shown in FIG. 7 differs from the previous embodiment in that a recess 10 is formed in the flat part of the unprocessed portion 41a formed between the through groove 5 of the block convex body 4a, and the block body 4a and the metal plate are 4b in that they are not fitted into each other through recesses.

According to the embodiment shown in FIG. 7, since the recess 10 formed in the block body 4a is filled with a large amount of brazing material, more reliable and strong close contact can be achieved.

In this embodiment, the recess 10 formed in the block body 4a can be formed not only by the electric discharge machining method but also by the cutting method.

In the embodiment shown in FIG. 7, a brazing filler metal was used.

Note that a paste brazing material may be used, or the metal plate 4b may be coated with the brazing material by plating.

The embodiment shown in FIG. 8 is a combination of the embodiment shown in FIG. 6 and the embodiment shown in FIG. 7.

In this way, if the recesses 10 and 4lb are provided in both the block body 4a and the metal plate 4b and the concave portions 10 and 4lb are brought into contact with each other and brazed, the strength of the brazed joint is higher than in the above-mentioned embodiment. .

Note that the present invention is not limited to the above-mentioned embodiments, and can be modified in various ways as described below.

(1) Although the openings 6 were made to face every other intersection of the molding grooves 1, they may be made so as to face every other intersection.

(2) The materials may be changed from each other, such as making the metal plate 4b on which the molding groove 1 is formed a wear-resistant material and the block body 4a' a material having high tensile strength.

(3) Although the hole 6 is drilled before the through groove 5, the hole 6 may be formed after the through groove 5 and the shaped groove 1 are processed and the whole is heat treated to increase the hardness.

If this order is followed, the dimensions of the openings 6 will not be distorted by the heat treatment.

(4) Also, after processing the through groove 5, drill the opening 6,
The order may be such that the metal plate 4b is then joined.

(5) Although the openings 6 are arranged at the intersections of the through grooves 5, they may be arranged at the ridges.

This also applies to the molding groove 1.

(6) Although the through groove 5 and the molding groove 1 are designed to overlap with each other, they may be arranged so as to be intentionally shifted from each other.

(7) Although the cross-sectional shape of the molding groove 1 is square, it may be triangular, hexagonal, octagonal, rectangular, or the like.

(8) The extrusion material of the molding die of the present invention is not limited to ceramic materials, but may of course be rubber materials or the like.

(9) The expression "metal plate" includes not only a metal plate as thin as about 3 cm as in the above embodiment, but also a metal plate that is thicker than that.

As detailed above, in the present invention, the plastic material from a large number of independent openings is passed through honeycomb-shaped through grooves.
- A method for manufacturing a honeycomb forming die used in a method of feeding into a honeycomb forming groove and continuously extruding a honeycomb-shaped formed body from this forming groove, the die being supplied into a flat part of a metal block body. A honeycomb-shaped through groove is machined, and a metal plate is used, and a recessed part having a shape corresponding to the flat part of the unprocessed part surrounded by the through grooves of the block body is formed in the metal plate. The concave part of this metal plate is fitted into the unprocessed part of the block body, and the two are joined by brazing, and the honeycomb molding groove is machined in this metal plate so as to communicate with the through groove. Compared to the conventional method of machining a through groove on the outer circumferential surface of a block body, machining a through groove on a block body can be done in a shorter time and more easily, and even if electrical discharge machining is used, for example, the groove width will not change. Therefore, it is possible to provide a die having through grooves with high dimensional accuracy.

In addition, because of the high dimensional accuracy of the through-groove, there are no local differences in the supply ratio of the Oshide-cho No-cho plastic material to the honeycomb molding groove, and therefore the core part of the extrusion molded body is There is no variation in material density, and therefore cracks in the core portion of the molded body during firing can be prevented.

In addition, in the present invention, as described above, a recess is formed in the metal plate, and the two are joined by brazing with the recess fitted into the unprocessed part of the block body, so even if the surface precision of the metal plate is poor, Since the fitting part is reliably brazed and joined, the brazing strength of the metal plate is improved, and therefore there is no adverse effect on the two-cam molded body that is extruded.

Further, in the present invention, since it is easy to increase the depth of the through groove in the material extrusion direction, the depth of the honeycomb forming groove relative to the metal plate can be reduced, and therefore the forming groove can be processed in a short time. It's easy to do.

Furthermore, according to the present invention, since the die is constructed by integrally joining the block body with the through groove and the metal plate with the molding groove, the material of each member can be adjusted to the function of the through groove and the molding groove. You can choose the one that is suitable for you.

Furthermore, in the present invention, a recess is provided in the flat surface of the unprocessed portion of the block body, a metal plate is brazed and joined to the non-processed portion side of the block body, and a hole communicating with the through groove is formed in the metal plate.・Since the Nikum molding groove is processed, the recess between the metal plate and the flat part of the non-processed part is filled with molten brazing filler metal during brazing, which increases the brazing strength of the metal plate. improves.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional perspective view showing a die manufactured by an embodiment of the method of the present invention, FIG. 2 is a front view of FIG. 1, FIG. 3 is a sectional view taken along line A-A in FIG. 2, and FIG. 1 is a perspective view showing a honeycomb-shaped molded body formed by the die shown in FIG. 1, and FIG.
6a to 6g are side sectional views showing stepwise an embodiment of the method of the present invention for manufacturing the die shown in FIG. 1, and FIGS. 7 and 8 are FIG. 3 is a cross-sectional view showing a die manufactured by another embodiment of the method of the present invention. 1...Honeycomb groove, 2...Die front surface, 3...Die back surface, 6...Open hole, 7...Joining Part, 4a...Dice body, 4al...Flock body, 41a...
Unprocessed part, 4b...Metal plate, 4lb...
... recess, 5 ... through groove, 10 ... recess.

Claims (1)

[Scope of Claims] 1. Plastic material from a large number of independent openings is transferred to the rear stage of the through-holes through a Zuru-Nicum-shaped through groove that communicates with the latter stage of the openings and perpendicularly to the openings. This is used in a method for continuously extruding a bicam-shaped molded body from this molding groove by supplying it into a one-cam molding groove that communicates with the through-groove at a position overlapping with the through-groove. A method for manufacturing a Nicum molding die, the method comprising: machining the above-mentioned Nicum-shaped through groove in a flat part of a metal block body, using a metal plate separate from the metal block body, and forming the block forming a recessed portion having a shape corresponding to a flat portion of the unprocessed portion formed between the through grooves of the body;
The metal plate and the block body are joined by brazing with the concave portion of the metal plate fitted into the unprocessed portion of the block body, and the one-nicum molding is formed on the metal plate to communicate with the through groove. A method for manufacturing a nicum molding die characterized by machining a groove. 2. The method according to claim 1, wherein the opening is formed in the block body before forming the through groove. 3. The method according to claim 1, wherein the openings are formed in the block body after forming the through grooves and before joining the metal plates. 4. The method according to claim 1, wherein the openings are formed in the block body after forming the honeycomb molding grooves in the metal plate. 5. The plastic material from a large number of independent openings is passed through a through groove in the shape of a zigzag that communicates with the opening after the opening and perpendicularly to the opening, and then passes through the through groove after the opening and overlapping the through groove. It is supplied into a sliding groove that communicates with the through groove at the lapping position, and is used in a method for extracting and molding a nicum-shaped molded body continuously from this forming groove.A die for dicing forming is manufactured. The method includes machining the honeycomb-shaped through grooves in a flat part of a metal block body, forming a recess in a flat part of an unprocessed part formed between the through grooves of the block body, and A metal plate is brazed and joined to the side where the through groove is processed,
A method for manufacturing a honeycomb molding die, characterized in that the honeycomb molding groove is machined in the metal plate so that the through groove communicates with the honeycomb molding groove. 6. The method according to claim 5, wherein the opening is formed in the block body before forming the through groove. 7. The method according to claim 5, wherein the opening is formed in the block body after forming the through groove and before joining the metal plate. 8. The method according to claim 5, wherein the openings are formed in the block body after forming the Nicum molding groove in the metal plate.