Method of manufacturing die

• US 6,621,034 B2
• Filed: 12/08/2000
• Issued: 09/16/2003
• Est. Priority Date: 12/10/1999
• Status: Active Grant

• Current Assignee: NGK Insulators Limited
• Original Assignee: NGK Insulators Limited
• Inventors: Kondo, Yoshimasa, Ishii, Takeyuki, Shibagaki, Yukinari
• Primary Examiner(s): Elve, M. Alexandra
• Assistant Examiner(s): EDMONDSON, LYNNE RENEE
• Application Number:
  US09/732,826
• Publication Number:
  US 20010004068A1
• Time in Patent Office: 1,012 Days
• Field of Search: 219/69.1, 219/69.12, 219/69.17, 219/68, 294/82, 425/461, 264/177.12, 264/177.11, 264/177.1
• US Class Current: 219/69.17
• CPC Class Codes: B23H 2200/30 for making honeycomb structures
• CPC Class Codes: B23H 9/00 Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects heat treatment by cathodic discharge C21D1/38
• CPC Class Codes: B23P 15/243 Honeycomb dies
• CPC Class Codes: B28B 3/269 For multi-channeled structures, e.g. honeycomb structures
• CPC Class Codes: B29C 48/11 comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29L 2031/60 Multitubular or multicompartmented articles, e.g. honeycomb

Abstract

The method includes the steps of preparing a die main body; performing batch supply hole machining with respect to one principal plane of the die main body to form batch supply holes; using a cutting apparatus to perform slit machining with respect to the other principal plane of the die main body to form slits; without removing the cutting apparatus from the die main body, continuously performing lateral hole machining to form the batch bold portions, which are arranged at least at intersecting portions in the die main body between the batch supply holes and the slits and are arranged corresponding to the slits; and there after removing the cutting apparatus from the die main body to thereby form an integral die. Alternatively, the above slit machining and continuously performing lacteral hole machining steps can be performed first and followed by performing the batch supply hole machining step.

Claims

1. A method of manufacturing a die having batch supply holes arranged at a batch supply side thereof, slits arranged at a batch discharge side thereof for forming the batch, and batch hold portions made of lateral holes, which are arranged at least at intersecting portions between the batch supply holes and the slits and are arranged corresponding to the slits, said method comprising the steps of:

(a) preparing a die main body;

(b) performing batch supply hole machining with respect to one principal plane of the die main body to form the batch supply holes;

(c) using a cutting apparatus to perform slit machining with respect to the other principal plane of the die main body to form the slits;

(d) without removing the cutting apparatus from the die main body, continuously performing lateral hole machining to form the batch hold portions, which are arranged at least at intersecting portions in the die main body between the batch supply holes and the slits and are arranged corresponding to the slits; and

(e) thereafter removing the cutting apparatus from the die main body to thereby form an integral die.

3. The method of manufacturing a die according to claim 1, wherein said lateral hole machining step is performed by at least one method selected from the group consisting of wire electric-discharge machining, wire lap machining, water-jet machining and laser machining.

4. The method of manufacturing a die according to claim 1, wherein the manufactured die is used for extruding a thin wall honeycomb structural body having a rib thickness of not larger than 150 μ

m.

5. The method of manufacturing a die according to claim 1, wherein a width of the slit is not larger than 250 μ

m.

6. The method of manufacturing a die according to claim 1, wherein the manufactured die is used for extruding a honeycomb structural body having a cell open rate of not smaller than 75%.

7. The method of manufacturing a die according to claim 1, wherein the manufactured die is used for extruding a honeycomb structural body having a cell density of not larger than 1800 cell/inch².

2. A method of manufacturing a die having batch supply holes arranged at a batch supply side thereof, slits arranged at a batch discharge side thereof for forming the batch, and batch hold portions made of lateral holes, which are arranged at least at intersecting portions between the batch supply holes and the slits and are arranged corresponding to the slits, said method comprising the steps of:

(a) preparing a die main body;

(b) using a cutting apparatus to perform slit machining with respect to one principal plane of the die main body to form the slits;

(c) without removing the cutting apparatus from the die main body, continuously performing lateral hole machining to form the batch hold portions arranged corresponding to the slits in the die main body; and

(d) thereafter removing the cutting apparatus from the die main body and performing batch supply hole machining with respect to the other principal plane of the die main body to form the batch supply holes to thereby form an integral die.

8. The method of manufacturing a die according to claim 2, wherein said lateral hole machining step is performed by at least one method selected from the group consisting of wire electric-discharge machining, wire lap machining, water-jet machining, and laser machining.

9. The method of manufacturing a die according to claim 2, wherein the manufactured die is used for extruding a thin wall honeycomb structural body having a rib thickness of not larger than 150 μ

m.

10. The method of manufacturing a die according to claim 2, wherein a width of the slit is not larger than 250 μ

m.

11. The method of manufacturing a die according to claim 2, wherein the manufactured die is used for extruding a honeycomb structural body having a cell open rate of not smaller than 75%.

12. The method of manufacturing a die according to claim 2, wherein the manufactured die is used for extruding a honeycomb structural body having a cell density of not larger than 1800 cell/inch².

13. A method of manufacturing a die having batch supply holes arranged at a batch supply side thereof, slits arranged at a batch discharge side thereof for forming the batch, and batch hold portions made of lateral holes, which are arranged at least at intersecting portions between the batch supply holes and the slits and are arranged corresponding to the slits, said method comprising the steps of:

(a) preparing a die main body;

(b) performing batch supply hole machining with respect to one principal plane of the die main body to form the batch supply holes;

(c) using a wire electric-discharge machining apparatus to perform slit machining with respect to the other principal plane of the die main body to form the slits;

(d) without removing the wire electric-discharge machining apparatus from the die main body, continuously performing lateral hole machining to form the batch hold portions, which are arranged at least at intersecting portions in the die main body between the batch supply holes and the slits and are arranged corresponding to the slits; and

(e) thereafter removing the wire electric-discharge machining apparatus from the die main body to thereby form an integral die.

15. The method of manufacturing a die according to claim 13, wherein the manufactured die is used for extruding a thin wall honeycomb structural body having a rib thickness of not larger than 150 μ

m.

16. The method of manufacturing a die according to claim 13, wherein a width of the slit is not larger than 250 μ

m.

17. The method of manufacturing a die according to claim 13, wherein the manufactured die is used for extruding a honeycomb structural body having a cell open rate of not smaller than 75%.

18. The method of manufacturing a die according to claim 13, wherein the manufactured die is used for extruding a honeycomb structural body having a cell density of not larger than 1800 cell/inch².

14. A method of manufacturing a die having batch supply holes arranged at a batch supply side thereof, slits arranged at a batch discharge side thereof for forming the batch, and batch hold portions made of lateral holes, which are arranged at least at intersecting portions between the batch supply holes and the slits and are arranged corresponding to the slits, said method comprising the steps of:

(a) preparing a die main body;

(b) using a wire electric-discharge machining apparatus to perform slit machining with respect to one principal plane of the die main body to form the slits;

(c) without removing the wire electric-discharge machining apparatus from the die main body, continuously performing lateral hole machining to form the batch hold portions arranged corresponding to the slits in the die main body; and

(d) thereafter removing the wire electric-discharge machining apparatus from the die main body and performing batch supply hole machining with respect to the other principal plane of the die main body to form the batch supply holes to thereby form an integral die.

19. The method of manufacturing a die according to claim 14, wherein the manufactured die is used for extruding a thin wall honeycomb structural body having a rib thickness of not larger than 150 μ

m.

20. The method of manufacturing a die according to claim 14, wherein a width of the slit is not larger than 250 μ

m.

21. The method of manufacturing a die according to claim 14, wherein the manufactured die is used for extruding a honeycomb structural body having a cell open rate of not smaller than 75%.

22. The method of manufacturing a die according to claim 14, wherein the manufactured die is used for extruding a honeycomb structural body having a cell density of not larger than 1800 cell/inch².