A metal mold for manufacturing a honeycomb structure having a plurality of cell density regions and an annular boundary wall includes a honeycomb-like slit part, which is opened to an extrusion surface of a single metal mold body, that is formed of a plurality of cell slits for forming the plurality of cell density regions and an annular boundary slit for forming the boundary wall. Out of the plurality of cell slits, adjacent cell slits adjacent to the boundary slit have all corner portions formed in a round shape by the adjacent cell slits and the boundary slit.

An electrical discharge machining (EDM) electrodes and associated methods are provided. An EDM electrode includes a holder rotatable about a rotation axis and a plurality of electrode elements attached to the holder and circumferentially arranged around the rotation axis. Respective positions of the electrode elements are radially adjustable relative to the rotation axis.

A honeycomb extrusion die body (401) including inlet (414) and exit (402) faces, and a plurality of pins (406) on the exit face (402) defining a matrix of intersecting wide slots (425) and narrow slots (427). The wide slots (425) have an exit width (W1) greater than an exit width (W2) of the narrow slots (427). The die body (401) further includes feedholes (422) at the inlet face (414) and intersecting with inlet portions (416) to the wide slots (425) and/or the narrow slots (427). Some of the pins (406) defining the wide slots (425) include a first surface indentation feature (430) that is (i) located between the inlet portion (416) and the wide slot exit and (ii) spaced away from the wide slot exit. Some of the pins (406) defining the narrow slots (427) include a second surface indentation feature (434) that is (i) located between the inlet portion and the narrow slot exit and (ii) spaced away from the narrow slot exit.

Methods of manufacturing honeycomb-structure-forming extrusion dies having a number of slots for use in producing extruded articles having complex honeycomb patterns and extrusion dies for use in the manufacture of extruded honeycomb bodies. The method includes inserting a die insert having a runner and a number of teeth into a slot of an extrusion die such that each of the teeth blocks at least a portion of the slot of the extrusion die. The method further includes separating the runner from the teeth so that the teeth remain within the slot of the extrusion die.

An extrusion die (100) for a honeycomb body, the die (100) including: an input surface (102); an opposing output surface (104); feed holes (108) extending from the input surface (102) toward the output surface (104); discharge slots (106) having a slot width (SW) and a slot length (SL), and extending from the output surface (104) toward the input surface (102); and a plenum (130) fluidly connecting the feed holes (108) and the discharge slots (106). The plenum (130) may include chambers (132) connected to the feed holes (108) and including tapered outlets (134) connected to the discharge slots (106). The plenum (133) may include first chambers (132A) connected to the feed holes (108) and including first tapered outlets (134A), and second chambers (132B) connected to the first outlets and including second tapered outlets (134B) connected to the discharge slots (106).

An apparatus and method to machine cavities in die blanks having little to no taper. The apparatus includes an electrode tool (200) including intersecting walls coated with electrically insulating coating (258), an erosion face (204) comprising a cross section of the walls exposed through the electrically insulating coating, and a channel formed by the walls to supply electrolyte to the erosion face, the channels defined by interior surfaces of the walls and having an opening formed by edges of the erosion face. The method includes pulsed electrochemical machining a work piece with the electrode tool.

An electrode for electrical discharge machining which makes it possible to form slits of a honeycomb structure forming die so that a slit width on a front surface side is smaller than a slit width on a back hole side is provided. The electrode for electrical discharge machining includes: plural plate-shaped discharge portions with a thickness that is gradually increased toward tips thereof; and a plate-shaped support portion to which end portions of the plural discharge portions on a side opposite to the tips are connected, wherein a difference between a thickness of the tip; and a thickness of the end portion on the side opposite to the tip ranges from 5 m to 500 m in the discharge portion.

Methods of manufacturing honeycomb-structure-forming extrusion dies having a number of slots for use in producing extruded articles having complex honeycomb patterns and extrusion dies for use in the manufacture of extruded honeycomb bodies. The method includes inserting a die insert having a runner and a number of teeth into a slot of an extrusion die such that each of the teeth blocks at least a portion of the slot of the extrusion die. The method further includes separating the runner from the teeth so that the teeth remain within the slot of the extrusion die.

A metal mold for manufacturing a honeycomb structure having a plurality of cell density regions and an annular boundary wall includes a honeycomb-like slit part, which is opened to an extrusion surface of a single metal mold body, that is formed of a plurality of cell slits for forming the plurality of cell density regions and an annular boundary slit for forming the boundary wall. Out of the plurality of cell slits, adjacent cell slits adjacent to the boundary slit have all corner portions formed in a round shape by the adjacent cell slits and the boundary slit.

A component is provided. The component includes a structure including a plurality of unit cells joined together, each unit cell of the plurality of unit cells having a mass density substantially similar to the mass density of every other unit cell of the plurality of unit cells. The plurality of unit cells includes a first portion of unit cells having a characteristic dimension and a first portion average stiffness, the characteristic dimension of the first portion of unit cells having a first value. The plurality of unit cells also includes a second portion of unit cells having the characteristic dimension and a second portion average stiffness, the characteristic dimension of the second portion of unit cells having a second value different from the first value, wherein the second portion average stiffness differs from the first portion average stiffness.