JP4062920B2 - Manufacturing method of mold for forming honeycomb structure - Google Patents

Manufacturing method of mold for forming honeycomb structure Download PDF

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JP4062920B2
JP4062920B2 JP2001397717A JP2001397717A JP4062920B2 JP 4062920 B2 JP4062920 B2 JP 4062920B2 JP 2001397717 A JP2001397717 A JP 2001397717A JP 2001397717 A JP2001397717 A JP 2001397717A JP 4062920 B2 JP4062920 B2 JP 4062920B2
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honeycomb structure
supply hole
forming
groove
slit groove
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JP2003011111A (en
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武 福嶋
章 佐々木
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Denso Corp
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Denso Corp
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Priority to JP2001397717A priority Critical patent/JP4062920B2/en
Priority to US10/059,245 priority patent/US6765174B2/en
Priority to DE10204428A priority patent/DE10204428B4/en
Priority to BE2002/0066A priority patent/BE1016830A5/en
Publication of JP2003011111A publication Critical patent/JP2003011111A/en
Priority to US10/857,943 priority patent/US7164098B2/en
Priority to BE2007/0286A priority patent/BE1017633A5/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
    • B28B3/26—Extrusion dies
    • B28B3/269—For multi-channeled structures, e.g. honeycomb structures

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Laser Beam Processing (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Description

【０００１】
【技術分野】
本発明は，薄肉のハニカム構造体を押出成形するための成形用金型に関するものである。
【０００２】
【従来技術】
例えばコーディエライト等を主成分としたセラミック製のハニカム構造体は，成形用金型を用いて材料を押出成形することにより製造される。このハニカム構造体は，隔壁を格子状に設けて多数のセルを構成してなり，そのセル形状としては例えば四角形，六角形等がある。
そして，上記ハニカム構造体成形用金型としては，材料を供給するための供給穴と，供給穴に連通し材料を上記ハニカム形状に成形するためのスリット溝とを有するハニカム構造体成形用金型が用いられる。
【０００３】
上記ハニカム構造体としては，近年その隔壁の薄肉化，例えば１００μｍ以下の薄肉化が求められている。これに対応して，上記ハニカム構造体成形用金型のスリット溝の溝幅も当然に幅狭化が求められている。
【０００４】
【解決しようとする課題】
しかしながら，ハニカム構造体成形用金型のスリット溝の溝幅を狭くすれば，上記供給穴から供給され材料がスリット溝を通過する際の材料流れが悪化する。そのため，成形時の成形圧力が増大し，成形性が低下するおそれがある。
【０００５】
本発明は，かかる従来の問題点に鑑みてなされたもので，成形性を低下させることなく，薄肉のハニカム構造体を成形することができるハニカム構造体成形用金型及びその製造方法を提供しようとするものである。
【０００６】
【課題の解決手段】
少なくとも，材料を供給するための供給穴と，該供給穴に連通し材料をハニカム形状に成形するためのスリット溝とを有するハニカム構造体成形用金型において，
上記スリット溝の底部と上記供給穴の側面とが交わって形成される角部に傾斜部が設けられており，該傾斜部においては，上記スリット溝の深さが上記供給穴に近づくにしたがって徐々に深くなっていることを特徴とするハニカム構造体成形用金型がある。
【０００７】
上記ハニカム構造体成形用金型は，上記のごとく，スリット溝の深さが均一ではなく，上記角部に傾斜部を設けて，スリット溝の深さを上記供給穴に近づくに従って深くしてある。そのため，供給穴からスリット溝に抜ける材料の流れをスムーズにすることができる。
【０００８】
すなわち，上記スリット溝の底部と供給穴の側面とが交差する上記角部が傾斜しているので，供給穴からスリット溝に抜ける材料が，上記傾斜部に沿って徐々に広がる。そのため，上記角部に傾斜部がない場合と比べて，材料が幅方向に広がる際の流れ方向の変化を小さくすることができる。それ故，材料が供給穴からスリット溝に侵入する際の材料流れをスムーズにすることができる。
そして，それ故，上記スリット溝の溝幅を狭幅化した場合においても，成形圧力の増大等を抑制することができ，優れた成形性を維持することができる。
【０００９】
本発明は，少なくとも，材料を供給するための供給穴と，該供給穴に連通し材料をハニカム形状に成形するためのスリット溝とを有するハニカム構造体成形用金型を製造する方法において，
金型素材の穴形成面から上記供給穴を形成した後，
該穴形成面と反対側の溝形成面の溝形成位置に対して水を噴射して水柱を形成すると共に，該水柱の中を通してレーザ光を照射し，該レーザ光の照射位置を上記溝形成位置に沿って移動させて同じ溝形成位置を複数回通過させる照射スキャンを行い，
かつ，形成される上記スリット溝の底部と上記供給穴の側面とが交わって形成される角部近傍において上記照射スキャンの回数を増やし，上記スリット溝の深さが上記供給穴に近づくにしたがって徐々に深くなる傾斜部を設けることを特徴とするハニカム構造体成形用金型の製造方法（請求項１）にある。
【００１０】
本発明においては，上記のごとく，スリット溝の加工に上記水柱の中を通すレーザ光を用いる。そして，このレーザ光を上記のごとく照射スキャンさせることにより徐々に溝深さを深くする。
このようなレーザ加工方法を採用することによって，局部的に照射スキャンの回数を変更することにより，局部的に溝深さを変更することができる。
【００１１】
そのため，本発明では，この照射スキャン回数の変化によって，上記スリット溝の底部と供給穴の側面とが交わって形成される角部近傍において，上記照射スキャンの回数を増やす。これにより，上記角部に傾斜部を形成し，供給穴に近づくほどスリット溝の深さを深くすることができる。
【００１２】
また，本発明では，上記のごとく水柱の中を上記レーザ光を通して照射する。これにより，レーザ光が上記水柱の径内に収まった状態で進行し，溝幅を上記水柱の径内に精度よく制御することができる。それ故，上記ハニカム構造体成形用金型に要求される精度に十分対応できる高精度のスリット溝加工を行うことができる。
【００１３】
このように，本発明では，上記レーザ加工方法を積極的に採用することにより，従来の研削方法或いは放電加工方法では極めて困難であった局部的な溝深さの変更を実現した。そして，特に上記角部に傾斜部を形成するように溝深さを変化することにより，上記のごとく材料流れのスムーズなハニカム構造体成形用金型を得ることができる。
【００１４】
【発明の実施の形態】
上記ハニカム構造体成形用金型における上記角部の傾斜部は，例えば，いわゆる面取りを行った場合のような非常に微細な傾斜でもよいし，比較的長いテーパ状のものでもよい。さらに，上記傾斜部分が直線であっても，曲線状であってもよい。
また，上記スリット溝の配置は，四角形格子状，あるいは六角形格子状等，様々な配置をとることができる。
【００１５】
また，スリット溝の溝幅としては，例えば２０〜１５０μｍという狭い幅寸法を採用することができる。この場合にも，上記のごとく成形材料のスムーズな流れを確保することができる。また，上記スリット溝の溝深さは，溝幅の１０倍以上に設定することもできる。この場合にも，上記角部の傾斜が有効に作用し，成形材料の流れの悪化を抑制することができる。
【００１６】
また，本発明において，上記レーザ光の照射位置の移動は，相対速度１５０ｍｍ／分以上で行うことが好ましい（請求項２）。これにより，レーザ光を照射して溶融した溶融部を容易に分離除去しながら少しずつ溝加工を進めることができる。一方，上記相対速度が１５０ｍｍ／分未満の場合には，上記溶融部の分離除去が十分に行われず，溝形成の能率が低下するという問題がある。
【００１７】
また，本発明において，上記傾斜部は，上記供給穴の側面との距離が０．５ｍｍ以内の範囲において設けることが好ましい（請求項３）。この場合には，上記傾斜部の形成を比較的容易に行うことができる。
【００１８】
また，上記傾斜部は，上記供給穴の側面との距離が０．３ｍｍ以上の範囲にわたって設けられており，その最終深さは０．３ｍｍ以上であることが好ましい（請求項４）。
この場合には，上記傾斜部の存在による材料流れをスムーズにする効果を十分に発揮することができる。
【００１９】
【実施例】
（実施例１）
本発明の実施例につき，図１〜図３を用いて説明する。
本例のハニカム構造体成形用金型８は，図１，図２に示すごとく，少なくとも，材料を供給するための供給穴８１と，該供給穴８１に連通し材料をハニカム形状に成形するためのスリット溝８２とを有するハニカム構造体成形用金型である。そして本例のハニカム構造体成形用金型８においては，スリット溝８２の底部８２０と供給穴８１の側面８１０とが交わって形成される角部に傾斜部８５が設けられており，該傾斜部８５においては，スリット溝８２の深さが上記供給穴８１に近づくにしたがって徐々に深くなっている。
【００２０】
このハニカム構造体成形用金型８を製造するに当たっては，図３に示すレーザ加工装置３を用いる。このレーザ加工装置３は，レーザ光を発生させるレーザ発生部３１と発生したレーザ光を所望の径に絞るレーザヘッド３２と，これらの間を結びレーザ光を導く光ファイバー部３３と，レーザ光１の周囲において噴射する水柱１８用の高圧水をレーザヘッド３２部分に供給する高圧水供給部３５と，高圧水を水柱１８として噴射するノズル３６とを有する。
また，金型素材７を保持すると共に平面上で移動可能なベッド３８を有する。このベッド３８に内蔵されたベッド駆動部，高圧水供給部３５，およびレーザ発生部３１はこれらを操作するための操作盤３９に接続されている。
【００２１】
金型素材７は，同図に示すごとく，厚さ１５ｍｍ，幅×長さが２００×２００ｍｍの四角形の金属板であり，材質はＳＫＤ６１よりなる。もちろん，これと異なるサイズ，材質の金型素材を用いることも可能である。
この金型素材７に対して，本例では，幅０．１ｍｍ，深さ２．０ｍｍのスリット溝を形成する。また，本例では，スリット溝８２の加工の前に，予めドリルにより供給穴８１を設けた。
【００２２】
そして，図示しない支持装置に上記金型素材７を平面方向に移動可能に保持する。そして，図３の矢印Ａの方向に金型素材７を移動させながら，レーザ加工装置３から金型素材７における溝形成面の溝形成位置に対して水を噴射して水柱１８を形成すると共に，該水柱１８の中を通してレーザ光１を照射する。さらに，レーザ光１の照射位置を上記溝形成位置に沿って移動させて同じ溝形成位置を複数回通過させる照射スキャンを行う。
【００２３】
このとき，金型素材７の移動速度は，１５０ｍｍ／分以上の２４０ｍｍ／分とした。そして，まず全ての溝形成位置を偏り無く１５０回通過するように照射スキャンした。これにより，上記のごとく幅０．１ｍｍ，深さ２．０ｍｍのサイズを有する幅狭深底のスリット溝８２が得られた。
【００２４】
さらに本例では，形成されたスリット溝８２の底部８２０と供給穴８１の側面８１０とが交わって形成される角部の近傍において，供給穴８１に近づくほどスキャン回数が多くなるように照射回数を増やした。これにより，図２に示すごとく，上記角部に傾斜部８５が得られ，スリット溝８２の深さが，供給穴８１に近づくにしたがって徐々に深くなるように加工された。
【００２５】
次に，本例の作用効果につき説明する。
本例のハニカム構造体成形用金型８は，上記のごとく，スリット溝８２の深さが均一ではなく，角部を傾斜させて傾斜部８５を形成し，スリット溝８２の深さを供給穴８１に近づくに従って深くしてある。そのため，供給穴８１からスリット溝８２に抜ける材料の流れをスムーズにすることができる。
【００２６】
すなわち，上記スリット溝８２の底部８２０と供給穴８１の側面８１０とが交差する角部が傾斜しているので，供給穴８１からスリット溝に抜ける材料が，傾斜部８５に沿って徐々に広がる。そのため，角部に傾斜部８５がない場合と比べて，材料が幅方向に広がる際の流れ方向の変化を小さくすることができる。それ故，材料が供給穴８１からスリット溝８２に侵入する際の材料流れをスムーズにすることができる。そして，それ故，上記のごとくスリット溝８２の溝幅が０．１ｍｍと狭い場合においても，成形圧力の増大等を抑制することができ，優れた成形性を維持することができる。
【００２７】
また，このような優れたハニカム構造体成形用金型８のスリット溝８２を加工するに当たり，上記の独特な加工方法を採用している。すなわち，水柱１８の中を通すレーザ光１を用い，その照射スキャン回数を局部的に変更する。これにより，局部的に溝深さを変更することができる。
【００２８】
そして本例では，この照射スキャン回数の増加を上記角部の近傍において行う。これにより，容易に上記傾斜部８５を形成することができ，供給穴８１に近づくほどスリット溝８２の深さが深くなる形状得ることができるのである。
そして，このような有利な点は，従来より行われていた研削方法或いは放電加工方法では得ることが困難である。
【００２９】
（比較例１）
比較例１は，図４に示すごとく，スリット溝８２の加工方法を従来よりある放電加工方法に変更し，スリット溝８２の深さを均一にしたハニカム構造体成形用金型９の例である。その他の構造は実施例１と同様である。
この比較例１のハニカム構造体成形用金型９及び上記実施例１のハニカム構造体成形用金型８を用いてハニカム構造体を押出成形した場合の材料の流れ方を図２，図４に示す。なお，上記ハニカム構造体用のセラミック材料としては，例えば，コーディエライトの原料となる複数の粉末とバインダーを混練したものがある。また原料粉末の粒径としては６０μｍ以下のものを採用することができる。
【００３０】
図４に示すごとく，従来のハニカム構造体成形用金型９の場合には，スリット溝８２の深さが均一に形成されているので，供給穴８１に矢印Ｂ方向に供給された成形材料の流れは，スリット溝８２と交わる角部で直角の矢印Ｄ方向に変更された後，スリット溝８２内での成形材料同士の衝突により矢印Ｅ方向に変更されてスリット溝８２から押出成形される。
【００３１】
一方，図２に示すごとく，本発明のハニカム構造体成形用金型８の場合には，上記傾斜部８５を有しており，スリット溝８２の深さが供給穴８１に近づくにしたがって徐々に深くなっているので，供給穴８１に矢印Ｂ方向に供給された成形材料の流れは，スリット溝８２と交わる角部で上記傾斜部８５の傾斜に沿って，矢印Ｃ方向に流れを変える。そして，最終的に矢印Ｅ方向に変更されてスリット溝８２から押出成形される。
【００３２】
このように，実施例１のハニカム構造体成形用金型を用いた場合には，比較例１のハニカム構造体成形用金型を用いた場合よりも材料流れの方向変化量が少ないので，変形圧力の増加を抑制することができる。そのため，スリット溝幅が狭くなっても優れた成形性を維持することができる。
【００３３】
（実施例２）
本例では，図５に示すごとく，六角形格子状のスリット溝８２を有するハニカム構造体成形用金型８を製造する例である。
この場合には，実施例１におけるレーザ光１の照射スキャン経路を工夫して，その軌跡が六角形格子状となるようにした。その他は実施例１と同様である。
この場合にも実施例１と同様の作用効果が得られる。
【００３４】
（実施例３）
本例では，実施例１と同様に，ハニカム構造体成形用金型８に傾斜部８５を設け，その形状を定量的に測定した。
図６に示すごとく，本例のハニカム構造体成形用金型８は，供給穴８１の直径を１ｍｍ，供給穴のピッチを２ｍｍとすると共に，実施例１と同様にして傾斜部８５を設けた。なお，スリット溝８２の幅は実施例１と同様に０．１ｍｍである。
【００３５】
本例の傾斜部８５は，同図に示すごとく，上記供給穴８１の側面８１０との距離Ｌが０．３ｍｍ以上の範囲にわたって設けられており，その最終深さＤ（ダレ距離）は０．３ｍｍ以上である。
【００３６】
本例では，比較のために，図７に示すごとく，上記スリット溝８２の形成を研削加工に変更し，傾斜部を有していない構造のハニカム構造体成形用金型９を作製した。そして，上記本例のハニカム構造体成形用金型８（本発明品）と比較のためのハニカム構造体成形用金型９（比較品）とを用いて実際に押出成形を行い，比較した。
【００３７】
比較の結果，本発明品の場合には，比較品に比べて，材料の流れがスムーズになり，優れた押出成形性が得られた。
この結果から，上記のごとく，少なくともスリット溝８２の幅が０．１ｍｍの場合には，供給穴８１の側面８１０との距離Ｌが０．３ｍｍ以上の範囲にわたって設けられており，その最終深さＤ（ダレ距離）は０．３ｍｍ以上であるような傾斜部８５を設けることによって，供給穴８１からスリット溝８２への材料の流れ性を向上させることができることが分かった。
【００３８】
また，この結果，従来と同様の材料の流れ性でよい場合には，スリット溝８２の深さを浅くしても十分に流れ性を確保することができる。そのため，例えば，上記ダレ距離Ｄの１／３程度の距離について，スリット溝８２の深さを小さくすることができるので，加工時の能率を向上させることができる。
【図面の簡単な説明】
【図１】実施例１におけるハニカム構造体成形用金型の，（ａ）平面図，（ｂ）要部拡大図。
【図２】実施例１におけるハニカム構造体成形用金型の，図１のＡ−Ａ線矢視から見た断面図。
【図３】実施例１におけるレーザ加工装置の構成を示す説明図。
【図４】比較例１におけるハニカム構造体成形用金型の断面図。
【図５】実施例２におけるハニカム構造体成形用金型の，（ａ）平面図，（ｂ）要部拡大図。
【図６】実施例３におけるハニカム構造体成形用金型の傾斜部の拡大説明図。
【図７】比較例におけるハニカム構造体成形用金型の傾斜部の拡大説明図。
【符号の説明】
１．．．レーザ光，
３．．．レーザ加工装置，
７．．．金型素材，
８．．．ハニカム構造体成形用金型，
８１．．．供給穴，
８１０．．．側面，
８２．．．スリット溝，
８２０．．．底部，[0001]
【Technical field】
The present invention relates to a molding die for extruding a thin honeycomb structure.
[0002]
[Prior art]
For example, a ceramic honeycomb structure mainly composed of cordierite or the like is manufactured by extruding a material using a molding die. This honeycomb structure is formed of a large number of cells by providing partition walls in a lattice shape, and examples of the cell shape include a quadrangle and a hexagon.
The honeycomb structure molding die is a honeycomb structure molding die having a supply hole for supplying a material and a slit groove communicating with the supply hole to form a material into the honeycomb shape. Is used.
[0003]
In recent years, the honeycomb structure has been required to have a thinner partition wall, for example, a thickness of 100 μm or less. Correspondingly, the groove width of the slit groove of the honeycomb structure molding die is naturally required to be narrowed.
[0004]
[Problems to be solved]
However, if the groove width of the slit groove of the mold for forming a honeycomb structure is reduced, the material flow when the material supplied from the supply hole passes through the slit groove is deteriorated. Therefore, the molding pressure at the time of molding may increase, and the moldability may be reduced.
[0005]
The present invention has been made in view of such conventional problems, and it is intended to provide a die for forming a honeycomb structure that can form a thin honeycomb structure without lowering the formability and a method for manufacturing the same. It is what.
[0006]
[Means for solving problems]
In a honeycomb structure molding die having at least a supply hole for supplying a material and a slit groove for forming the material into a honeycomb shape in communication with the supply hole,
An inclined portion is provided at a corner formed by the bottom portion of the slit groove and the side surface of the supply hole, and in the inclined portion, the depth of the slit groove gradually increases as the supply hole approaches the supply hole. There is a mold for forming a honeycomb structure characterized by being deepened.
[0007]
As described above, the mold for forming the honeycomb structure is not uniform in the depth of the slit groove, and is provided with an inclined portion at the corner, and the depth of the slit groove is increased toward the supply hole. . Therefore, the flow of the material that passes from the supply hole to the slit groove can be made smooth.
[0008]
That is, since the corner portion where the bottom of the slit groove intersects the side surface of the supply hole is inclined, the material that passes through the supply hole into the slit groove gradually spreads along the inclined portion. Therefore, the change in the flow direction when the material spreads in the width direction can be reduced as compared with the case where there is no inclined portion at the corner. Therefore, the material flow when the material enters the slit groove from the supply hole can be made smooth.
Therefore, even when the groove width of the slit groove is narrowed, an increase in molding pressure or the like can be suppressed, and excellent moldability can be maintained.
[0009]
The present invention provides a method for manufacturing a honeycomb structure molding die having at least a supply hole for supplying a material and a slit groove for forming the material into a honeycomb shape in communication with the supply hole.
After forming the supply hole from the hole forming surface of the mold material,
Water is sprayed onto the groove forming position on the groove forming surface opposite to the hole forming surface to form a water column, and laser light is irradiated through the water column, and the irradiation position of the laser light is defined as the groove forming position. Perform an irradiation scan that moves along the position and passes through the same groove forming position multiple times.
In addition, the number of irradiation scans is increased in the vicinity of a corner formed by the bottom of the slit groove formed and the side surface of the supply hole, and the depth of the slit groove gradually approaches the supply hole. In the manufacturing method of a die for forming a honeycomb structure, which is provided with a deepened inclined portion ( claim 1 ).
[0010]
In the present invention, as described above, the laser beam that passes through the water column is used to process the slit groove. The groove depth is gradually increased by irradiating and scanning the laser light as described above.
By adopting such a laser processing method, the groove depth can be locally changed by locally changing the number of irradiation scans.
[0011]
Therefore, in the present invention, the number of irradiation scans is increased in the vicinity of the corner formed by the bottom of the slit groove and the side surface of the supply hole by the change in the number of irradiation scans. Thereby, an inclined part is formed in the said corner | angular part, and the depth of a slit groove | channel can be deepened, so that a supply hole is approached.
[0012]
In the present invention, the water column is irradiated through the laser beam as described above. As a result, the laser light travels in a state of being within the diameter of the water column, and the groove width can be accurately controlled within the diameter of the water column. Therefore, it is possible to perform highly accurate slit groove processing that can sufficiently cope with the accuracy required for the honeycomb structure molding die.
[0013]
As described above, in the present invention, by locally adopting the above laser processing method, a local groove depth change which has been extremely difficult with the conventional grinding method or electric discharge processing method has been realized. In particular, by changing the groove depth so as to form inclined portions at the corners, a honeycomb structure molding die having a smooth material flow can be obtained as described above.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
The inclined portion of the corner portion in the honeycomb structure forming mold may have a very fine inclination as in the case of so-called chamfering, or may have a relatively long taper shape. Furthermore, the inclined part may be a straight line or a curved line.
The slit grooves can be arranged in various ways such as a quadrangular lattice or a hexagonal lattice.
[0015]
Further, as the groove width of the slit groove, for example, a narrow width dimension of 20 to 150 μm can be adopted. Even in this case, a smooth flow of the molding material can be ensured as described above. Further, the groove depth of the slit groove can be set to 10 times or more of the groove width. Also in this case, the inclination of the corners acts effectively, and the deterioration of the flow of the molding material can be suppressed.
[0016]
In the present invention, the movement of the irradiation position of the laser light is preferably performed at a relative speed 150 mm / min or more (claim 2). As a result, the groove processing can be performed little by little while easily separating and removing the melted portion irradiated with the laser beam. On the other hand, when the relative speed is less than 150 mm / min, there is a problem in that the melted portion is not sufficiently separated and removed, and the efficiency of groove formation is reduced.
[0017]
Further, in the present invention, the inclined portion is preferably the distance between the side surface of the supply holes provided in the range within 0.5 mm (claim 3). In this case, the inclined portion can be formed relatively easily.
[0018]
Further, the inclined portion is provided over the range distance of more than 0.3mm between the side of the supply holes, it is preferred that the final depth is 0.3mm or more (claim 4).
In this case, the effect of smoothing the material flow due to the presence of the inclined portion can be sufficiently exerted.
[0019]
【Example】
Example 1
An embodiment of the present invention will be described with reference to FIGS.
As shown in FIGS. 1 and 2, the honeycomb structure molding die 8 of this example is provided with at least a supply hole 81 for supplying a material and a material communicating with the supply hole 81 to form a honeycomb shape. This is a honeycomb structure molding die having a slit groove 82. In the honeycomb structure forming mold 8 of this example, the inclined portion 85 is provided at the corner portion formed by the bottom portion 820 of the slit groove 82 and the side surface 810 of the supply hole 81 intersecting, and the inclined portion In 85, the depth of the slit groove 82 gradually increases as it approaches the supply hole 81.
[0020]
In manufacturing the honeycomb structure forming mold 8, a laser processing apparatus 3 shown in FIG. 3 is used. The laser processing apparatus 3 includes a laser generating unit 31 that generates laser light, a laser head 32 that narrows the generated laser light to a desired diameter, an optical fiber unit 33 that guides the laser light between them, and a laser beam 1 A high-pressure water supply unit 35 that supplies high-pressure water for the water column 18 to be jetted around the laser head 32 and a nozzle 36 that jets high-pressure water as the water column 18 are provided.
Moreover, it has the bed 38 which hold | maintains the metal mold | die material 7 and can move on a plane. The bed drive unit, the high-pressure water supply unit 35, and the laser generator unit 31 built in the bed 38 are connected to an operation panel 39 for operating them.
[0021]
The mold material 7 is a rectangular metal plate having a thickness of 15 mm and a width × length of 200 × 200 mm as shown in FIG. Of course, it is also possible to use a mold material of a different size and material.
In this example, a slit groove having a width of 0.1 mm and a depth of 2.0 mm is formed on the mold material 7. Further, in this example, the supply hole 81 is provided in advance by a drill before the slit groove 82 is processed.
[0022]
And the said mold raw material 7 is hold | maintained at the support apparatus which is not shown in figure so that a movement in a plane direction is possible. Then, while moving the mold material 7 in the direction of arrow A in FIG. 3, water is sprayed from the laser processing device 3 to the groove forming position on the groove forming surface of the mold material 7 to form the water column 18. The laser beam 1 is irradiated through the water column 18. Further, an irradiation scan is performed in which the irradiation position of the laser beam 1 is moved along the groove forming position and the same groove forming position is passed a plurality of times.
[0023]
At this time, the moving speed of the mold material 7 was set to 240 mm / min, which is 150 mm / min or more. First, irradiation scanning was performed so that all the groove forming positions passed 150 times without any deviation. As a result, the narrow and deep bottom slit groove 82 having a width of 0.1 mm and a depth of 2.0 mm was obtained as described above.
[0024]
Further, in this example, in the vicinity of the corner formed by the bottom portion 820 of the formed slit groove 82 and the side surface 810 of the supply hole 81, the number of times of irradiation is increased so that the number of scans increases as the supply hole 81 is approached. Increased. As a result, as shown in FIG. 2, inclined portions 85 are obtained at the corners, and the depth of the slit groove 82 is processed so as to gradually become deeper as the supply hole 81 is approached.
[0025]
Next, the effect of this example will be described.
As described above, the honeycomb structure molding die 8 of this example is not uniform in the depth of the slit groove 82, and the inclined portion 85 is formed by inclining the corner portion, and the depth of the slit groove 82 is set to the supply hole. It gets deeper as it gets closer to 81. Therefore, the flow of the material that passes from the supply hole 81 to the slit groove 82 can be made smooth.
[0026]
That is, since the corner portion where the bottom portion 820 of the slit groove 82 and the side surface 810 of the supply hole 81 intersect is inclined, the material that passes through the supply hole 81 into the slit groove gradually spreads along the inclined portion 85. Therefore, the change in the flow direction when the material spreads in the width direction can be reduced as compared with the case where the inclined portion 85 is not provided at the corner portion. Therefore, the material flow when the material enters the slit groove 82 from the supply hole 81 can be made smooth. Therefore, even when the groove width of the slit groove 82 is as narrow as 0.1 mm as described above, an increase in molding pressure or the like can be suppressed, and excellent moldability can be maintained.
[0027]
In addition, the above-described unique processing method is employed for processing the slit groove 82 of such an excellent honeycomb structure forming mold 8. That is, the laser beam 1 passing through the water column 18 is used, and the number of irradiation scans is locally changed. Thereby, the groove depth can be changed locally.
[0028]
In this example, the number of irradiation scans is increased in the vicinity of the corner. Thus, the inclined portion 85 can be easily formed, and a shape in which the depth of the slit groove 82 becomes deeper as the supply hole 81 is approached can be obtained.
Such advantages are difficult to obtain by a conventional grinding method or electric discharge machining method.
[0029]
(Comparative Example 1)
As shown in FIG. 4, Comparative Example 1 is an example of a honeycomb structure forming die 9 in which the slit groove 82 machining method is changed to a conventional electric discharge machining method, and the slit groove 82 has a uniform depth. . Other structures are the same as those in the first embodiment.
FIGS. 2 and 4 show how the material flows when the honeycomb structure is extruded using the honeycomb structure forming mold 9 of Comparative Example 1 and the honeycomb structure forming mold 8 of Example 1 described above. Show. The ceramic material for the honeycomb structure includes, for example, a material obtained by kneading a plurality of powders as a raw material for cordierite and a binder. Moreover, as a particle size of raw material powder, the thing of 60 micrometers or less is employable.
[0030]
As shown in FIG. 4, in the case of the conventional mold for forming a honeycomb structure 9, since the slit groove 82 is formed to have a uniform depth, the molding material supplied to the supply hole 81 in the direction of arrow B is formed. The flow is changed in the direction of a right-angled arrow D at the corner where it intersects with the slit groove 82, and then changed in the direction of arrow E due to collision of molding materials in the slit groove 82 and extruded from the slit groove 82.
[0031]
On the other hand, as shown in FIG. 2, the honeycomb structure molding die 8 of the present invention has the inclined portion 85 and gradually increases as the depth of the slit groove 82 approaches the supply hole 81. Since it is deeper, the flow of the molding material supplied to the supply hole 81 in the direction of arrow B changes the flow in the direction of arrow C along the inclination of the inclined portion 85 at the corner that intersects the slit groove 82. Then, it is finally changed in the direction of arrow E and extruded from the slit groove 82.
[0032]
As described above, when the honeycomb structure molding die of Example 1 is used, the amount of change in the direction of material flow is smaller than when the honeycomb structure molding die of Comparative Example 1 is used. An increase in pressure can be suppressed. Therefore, excellent formability can be maintained even when the slit groove width is narrowed.
[0033]
(Example 2)
In this example, as shown in FIG. 5, a honeycomb structure forming mold 8 having hexagonal lattice-shaped slit grooves 82 is manufactured.
In this case, the irradiation scan path of the laser beam 1 in the first embodiment is devised so that the locus becomes a hexagonal lattice shape. Others are the same as in the first embodiment.
In this case, the same effect as that of the first embodiment can be obtained.
[0034]
(Example 3)
In this example, as in Example 1, the inclined portion 85 was provided in the honeycomb structure forming mold 8 and the shape thereof was quantitatively measured.
As shown in FIG. 6, the honeycomb structure molding die 8 of this example has a diameter of the supply holes 81 of 1 mm, a pitch of the supply holes of 2 mm, and is provided with an inclined portion 85 as in the first embodiment. . The width of the slit groove 82 is 0.1 mm as in the first embodiment.
[0035]
As shown in the figure, the inclined portion 85 of the present example is provided over a range where the distance L between the supply hole 81 and the side surface 810 is 0.3 mm or more, and the final depth D (sag distance) is 0. 3 mm or more.
[0036]
In this example, for comparison, as shown in FIG. 7, the formation of the slit groove 82 was changed to grinding, and a honeycomb structure molding die 9 having a structure having no inclined portion was produced. Then, extrusion molding was actually performed using the honeycomb structure molding die 8 of the present example (product of the present invention) and the honeycomb structure molding die 9 for comparison (comparative product) for comparison.
[0037]
As a result of comparison, in the case of the product of the present invention, the material flow was smoother than that of the comparative product, and excellent extrusion moldability was obtained.
From this result, as described above, when at least the width of the slit groove 82 is 0.1 mm, the distance L with respect to the side surface 810 of the supply hole 81 is provided over a range of 0.3 mm or more, and its final depth It has been found that the flowability of the material from the supply hole 81 to the slit groove 82 can be improved by providing the inclined portion 85 whose D (sag distance) is 0.3 mm or more.
[0038]
As a result, when the flowability of the material is the same as that of the prior art, the flowability can be sufficiently ensured even if the depth of the slit groove 82 is reduced. Therefore, for example, the depth of the slit groove 82 can be reduced for a distance of about 1/3 of the sagging distance D, so that the efficiency during processing can be improved.
[Brief description of the drawings]
1A is a plan view and FIG. 1B is an enlarged view of a main part of a mold for forming a honeycomb structure in Example 1. FIG.
2 is a cross-sectional view of the honeycomb structure forming mold in Example 1 as viewed from the direction of arrows AA in FIG. 1;
3 is an explanatory diagram showing a configuration of a laser processing apparatus in Embodiment 1. FIG.
4 is a cross-sectional view of a honeycomb structure forming mold in Comparative Example 1. FIG.
5A is a plan view and FIG. 5B is an enlarged view of a main part of a mold for forming a honeycomb structure in Example 2. FIG.
6 is an enlarged explanatory view of an inclined portion of a honeycomb structure forming mold in Example 3. FIG.
FIG. 7 is an enlarged explanatory view of an inclined portion of a honeycomb structure forming mold in a comparative example.
[Explanation of symbols]
1. . . Laser light,
3. . . Laser processing equipment,
7). . . Mold material,
8). . . Mold for forming honeycomb structure,
81. . . Supply holes,
810. . . side,
82. . . Slit groove,
820. . . bottom,

Claims (4)

少なくとも，材料を供給するための供給穴と，該供給穴に連通し材料をハニカム形状に成形するためのスリット溝とを有するハニカム構造体成形用金型を製造する方法において，  In a method for manufacturing a die for forming a honeycomb structure having at least a supply hole for supplying a material and a slit groove for forming the material into a honeycomb shape in communication with the supply hole,
金型素材の穴形成面から上記供給穴を形成した後，  After forming the supply hole from the hole forming surface of the mold material,
該穴形成面と反対側の溝形成面の溝形成位置に対して水を噴射して水柱を形成すると共に，該水柱の中を通してレーザ光を照射し，該レーザ光の照射位置を上記溝形成位置に沿って移動させて同じ溝形成位置を複数回通過させる照射スキャンを行い，  Water is sprayed onto the groove forming position on the groove forming surface opposite to the hole forming surface to form a water column, and laser light is irradiated through the water column, and the irradiation position of the laser light is defined as the groove forming position. Perform an irradiation scan that moves along the position and passes through the same groove forming position multiple times.
かつ，形成される上記スリット溝の底部と上記供給穴の側面とが交わって形成される角部近傍において上記照射スキャンの回数を増やし，上記スリット溝の深さが上記供給穴に近づくにしたがって徐々に深くなる傾斜部を設けることを特徴とするハニカム構造体成形用金型の製造方法。  In addition, the number of irradiation scans is increased near the corner formed by the bottom of the slit groove formed and the side surface of the supply hole, and the depth of the slit groove gradually approaches the supply hole. A method for manufacturing a honeycomb structure molding die, characterized in that a deeply inclined portion is provided. 請求項１において，上記レーザ光の照射位置の移動は，相対速度１５０ｍｍ／分以上で行うことを特徴とするハニカム構造体成形用金型の製造方法。  2. The method for manufacturing a honeycomb structure molding die according to claim 1, wherein the movement of the laser beam irradiation position is performed at a relative speed of 150 mm / min or more. 請求項１又は２において，上記傾斜部は，上記供給穴の側面との距離が０．５ｍｍ以内の範囲において設けられていることを特徴とするハニカム構造体成形用金型の製造方法。  3. The method for manufacturing a honeycomb structure molding die according to claim 1, wherein the inclined portion is provided in a range within 0.5 mm from the side surface of the supply hole. 請求項１〜３のいずれか１項において，上記傾斜部は，上記供給穴の側面との距離が０．３ｍｍ以上の範囲にわたって設けられており，その最終深さは０．３ｍｍ以上であることを特徴とするハニカム構造体成形用金型の製造方法。  The inclined portion according to any one of claims 1 to 3, wherein the inclined portion is provided over a range of a distance of 0.3 mm or more from a side surface of the supply hole, and a final depth thereof is 0.3 mm or more. A method for manufacturing a die for forming a honeycomb structure.
JP2001397717A 2001-02-05 2001-12-27 Manufacturing method of mold for forming honeycomb structure Expired - Fee Related JP4062920B2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
JP2001397717A JP4062920B2 (en) 2001-04-27 2001-12-27 Manufacturing method of mold for forming honeycomb structure
US10/059,245 US6765174B2 (en) 2001-02-05 2002-01-31 Method for machining grooves by a laser and honeycomb structure forming die and method for producing the same die
DE10204428A DE10204428B4 (en) 2001-02-05 2002-02-04 Laser recess removal method and method of manufacturing a honeycomb molding tool
BE2002/0066A BE1016830A5 (en) 2001-02-05 2002-02-05 METHOD OF FORMING GROOVES BY MEANS OF A LASER, DIE FOR PRODUCING HONEYCOMB STRUCTURES AND METHOD FOR PRODUCING SAME.
US10/857,943 US7164098B2 (en) 2001-02-05 2004-06-02 Method for machining grooves by a laser and honeycomb structure forming die and method for producing the same die
BE2007/0286A BE1017633A5 (en) 2001-02-05 2007-06-08 PROCESS FOR PRODUCING A HONEYCOMB STRUCTURE FORMING DIE AND DIE THUS OBTAINED

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2001-133131 2001-04-27
JP2001133131 2001-04-27
JP2001397717A JP4062920B2 (en) 2001-04-27 2001-12-27 Manufacturing method of mold for forming honeycomb structure

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JP4062920B2 true JP4062920B2 (en) 2008-03-19

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