Brake disc sand box forming mold

Abstract

The invention relates to the technical field of sand mold casting, in particular to a brake disc sand box forming mold which comprises a sand box, a brake disc mold and a filling mold. A sand box is modeled through a brake disc mold and a filling mold, the filling mold is made of polystyrene foam, in the pouring process, the filling mold is heated and melted, a gas channel is formed in the sand box, the gas channel is communicated with hollow plates on the two sides of the sand box, and the hollow plates on the two sides of the sand box are communicated with the external atmosphere. Therefore, under the condition that air is introduced, indirect cooling of the brake disc poured in the sand box can be achieved. The method for cooling the brake disc by introducing air into the sand box is adopted, so that in the process, on one hand, the situation that the product quality is influenced due to high cooling speed when the brake disc is put into air for direct cooling after pouring is avoided; on the other hand, the conditions that the cooling time is long and the product quality is influenced during cooling in the sand box are avoided; and positive effects on improving the production efficiency and ensuring the product quality are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of sand casting, in particular to a brake disc sand box forming die. Background Art

[0002] The brake disc, also known as the brake disc, is a friction pair on the disc brake. It rotates with the wheels when the vehicle is moving. When the vehicle brakes, the caliper clamps the brake disc for friction braking, which slows down or stops the vehicle. The quality of the brake disc plays a vital role in driving safety.

[0003] Existing brake discs have different models and specifications, but the manufacturing process is all cast. During the process, molten iron is poured into a sand box mold. When the molten iron is cooled, a brake disc blank can be obtained, and then the brake disc product can be obtained after fine processing.

[0004] In the process of brake disc casting, the cooling method is particularly critical. Due to poor heat dissipation during cooling in the sand box, the cooling speed of the brake disc casting is slow, which affects the production efficiency on the one hand, and the coarser grains also affect the mechanical properties of the brake disc when the cooling speed is slow on the other hand. Therefore, in the existing production process, the cast brake disc is often placed in the air for cooling, which greatly improves the cooling efficiency and improves the production efficiency. However, when cooling in the air, the quality of the product is also difficult to guarantee. On the one hand, the temperature of the environment is difficult to effectively control. In summer and winter, the change of the external environment temperature also directly affects the quality of the product. On the other hand, when the brake disc casting is cooled too quickly, stress is generated due to uneven cooling, which is also easy to cause cracks or deformation in the product, seriously affecting the quality of the product.

[0005] Therefore, a brake disc sand box forming mold that can coordinate the cooling speed and cooling time during the brake disc production process, thereby effectively ensuring production efficiency while ensuring product quality, is a technical problem that needs to be solved. Summary of the invention

[0006] The purpose of the present invention is to provide a brake disc sand box forming mold to solve the problems that the product quality of the existing sand box mold is easily affected by the external environment when directly cooled by air, and the cooling time is long when cooled in the sand box, and the product quality cannot be guaranteed.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a brake disc sand box forming mold, comprising a sand box, a brake disc mold and a filling mold; The sand box includes an upper sand box and a lower sand box; The brake disc mold includes a first mold, a second mold and a third mold. The first mold cooperates with an upper sand box and performs sand box molding on the upper sand box. The third mold cooperates with a lower sand box and performs sand box molding on the lower sand box. The second mold is placed between the upper sand box and the lower sand box after molding. The filling mold is made of polystyrene foam, and the filling mold is matched with the upper sand box and the lower sand box respectively, and the filling mold does not interfere with the first mold and the third mold in space; The filling mold is heated and melted during pouring, and gas channels are formed in the upper flask and the lower flask respectively. Hollow plates are arranged on both sides of the upper flask and the lower flask, and vents are arranged on the inner sides of the hollow plates. The vents are matched with the filling mold. After the filling mold is melted, the vents are connected with the formed gas channels. The cast brake disc is indirectly cooled by passing air into the formed gas channels.

[0008] Furthermore, the gas channels formed in the upper flask and the lower flask are connected to each other.

[0009] Furthermore, a first hollow plate is provided on the front side of the upper sand box, an air extraction port is provided on the outer side of the first hollow plate, a first air vent is provided on the inner side of the first hollow plate, and the air extraction port and the first air vent are respectively connected to the cavity inside the first hollow plate; a second hollow plate is provided on the rear side of the upper sand box, a first air inlet is provided on the outer side of the second hollow plate, a second air vent is provided on the inner side of the second hollow plate, and a first channel is provided on the lower side of the second hollow plate, and the first air inlet, the second air vent and the first channel are respectively connected to the second hollow plate. The internal cavities are connected; a third hollow plate is arranged on the front side of the lower sand box, a second air inlet is arranged on the outer side of the third hollow plate, a third air vent is arranged on the inner side of the third hollow plate, and the second air inlet and the third air vent are respectively connected with the cavity inside the third hollow plate; a fourth hollow plate is arranged on the rear side of the lower sand box, a fourth air vent is arranged on the inner side of the fourth hollow plate, a second channel is arranged on the upper side of the fourth hollow plate, and the fourth air vent and the second channel are respectively connected with the cavity inside the fourth hollow plate; the first channel is connected with the second channel.

[0010] Furthermore, the number of the first air inlet holes is less than the number of the second air inlet holes.

[0011] Furthermore, the first hollow plate, the second hollow plate, the third hollow plate and the fourth hollow plate are all detachably provided with cleaning plates, and the installation openings of the cleaning plates after removal are communicated with the cavities inside the hollow plates.

[0012] Furthermore, the filling mold includes a first filling layer, in which a first connecting column is arranged. When the filling mold is placed, both ends of the first connecting column extend to the vents inside the hollow plates on the front and rear sides of the upper sand box or the lower sand box respectively.

[0013] Furthermore, a second filling layer and a third filling layer are respectively arranged on the upper and lower sides of the first filling layer, and the gas channels formed after the second filling layer and the third filling layer are melted are not connected to the hollow plates on both sides of the upper sand box or the lower sand box.

[0014] Furthermore, mutually interlaced and complementary limiting members are arranged below the upper flask and above the lower flask, and the limiting members are elastically and telescopically connected to the box body of the upper flask or the lower flask.

[0015] Furthermore, the limiting piece includes an angle piece, which is slidably connected to the box body of the upper sand box or the lower sand box, a connecting part is arranged on the inner side of the angle piece, a slide groove is arranged on the box body corresponding to the connecting part, a connecting bolt is installed in the slide groove through the connecting part from top to bottom, a spring is arranged below the connecting part, and the spring is sleeved on the connecting bolt.

[0016] Beneficial effects of the present invention: 1. The present invention adopts a filling component made of polystyrene foam material. On the one hand, the cost is low and it is easy to use in production. On the other hand, the filling component of this material is heated and melted during pouring to form a gas channel. During the process, since the filling component is located inside the sand mold, it is less in direct contact with the air, which can avoid a large amount of pollutants generated by combustion, effectively reduce the health hazards to operators and help maintain the workshop environment; 2. The present invention can quickly take away the heat inside the sand mold by connecting the air through the gas channel generated when the filling component is melted. At the same time, due to the heat preservation effect of the sand mold, the cooling process of the casting can be effectively controlled to avoid excessively fast or slow cooling, which helps to ensure the quality of the product; 3. The present invention provides the first air inlet hole and the second air inlet hole and adjusts the distribution of the first air inlet hole and the second air inlet hole so that the cooling speed of the brake disc casting remains relatively uniform at the top and bottom during the cooling process, thereby playing a positive role in improving the quality of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Schematic diagram of the existing brake disc structure (top view); Figure 2 is a schematic diagram of the existing brake disc structure (looking up); Figure 3 It is a schematic diagram of the structure of an existing brake disc mold; Figure 4 1 is a schematic diagram of the upper sand box structure of the present invention (front view); Figure 5 1. It is a schematic diagram of the upper sand box structure of the present invention (rear view); Figure 6 This is a schematic diagram of the upper sand box structure of the present invention (with Figure 4 Upside-down state); Figure 7 Schematic diagram of the lower sand box structure of the present invention (front view); Figure 8 Schematic diagram of the lower sand box structure of the present invention (rear view); Fig. 9 The present invention Figure 7 The schematic diagram of the installation structure of the position-limiting component after the partial enlargement of part A in the middle; Fig.10 It is a structural schematic diagram of the filling mold of the present invention.

[0018] The names corresponding to the marks in the figure are: 1. Brake disc; 11. Upper part; 12. Middle part; 13. Lower part; 2. Brake disc mold; 21. First mold; 22. Second mold; 23. Third mold; 3. Upper sand box; 31. First hollow plate; 311. First vent hole; 32. Second hollow plate; 321. Second vent hole; 322. First channel; 33. First cleaning plate; 331. Air extraction port; 34. Second cleaning plate; 35. First air inlet hole; 4. Lower sand box; 41. Third hollow plate; 411. First Three ventilation holes; 42, fourth hollow plate; 421, fourth ventilation hole; 422, second channel; 43, third cleaning plate; 44, second air inlet; 45, fourth cleaning plate; 5, limit piece; 51, angle piece; 511, connecting part; 52, slide groove; 53, connecting bolt; 54, spring; 6, filling mold; 61, first filling layer; 611, first connecting column; 62, second filling layer; 621, second connecting column; 63, third filling layer; 631, third connecting column; 64, connecting rod. DETAILED DESCRIPTION

[0019] The technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0020] Embodiments of the present invention: like Figure 1-2 As shown, it is a schematic diagram of the structure of an existing brake disc 1, which shows a ventilated brake disc 1, including an upper part 11, a lower part 13 and a middle part 12 located between the upper part 11 and the lower part 13, wherein the middle part 12 is fixedly connected to the upper part 11 and the lower part 13 respectively, wherein the middle part 12 is an air duct.

[0021] like Figure 2-3As shown, the existing brake disc mold 2 includes a first mold 21, a second mold 22 and a third mold 23, wherein the first mold 21 is adapted to the upper part 11, the third mold 23 is adapted to the lower part 13, and the second mold 22 is adapted to the middle part 12; the second mold 22 is a sand core.

[0022] like Figure 4-6 As shown, it is a schematic diagram of the structure of the upper sand box 3 of the present invention, wherein a first hollow plate 31 and a second hollow plate 32 are respectively arranged on the front and rear sides of the upper sand box 3; a first cleaning plate 33 is detachably installed on the outer side of the first hollow plate 31, and an air suction port 331 is installed on the first cleaning plate 33, and the air suction port 331 is connected to the inner cavity of the first hollow plate 31, and a first vent hole 311 is arranged on the inner side of the first hollow plate 31, and one side of the first vent hole 311 is connected to the inner cavity of the first hollow plate 31, and the other side of the first vent hole 311 is connected to the interior of the upper sand box 3; A second cleaning plate 34 is detachably installed on the outer side of the core plate 32, and a first air inlet hole 35 is arranged on the second hollow plate 32 and the second cleaning plate 34, and the first air inlet hole 35 is connected to the cavity inside the second hollow plate 32, and a second air vent 321 is arranged on the inner side of the second hollow plate 32, and one side of the second air vent 321 is connected to the cavity inside the second hollow plate 32, and the other side of the second air vent 321 is connected to the interior of the upper sand box 3; a first channel 322 is arranged below the second hollow plate 32, and the first channel 322 is connected to the cavity inside the second hollow plate 32.

[0023] like Figure 6-8 As shown, it is a schematic diagram of the structure of the lower sand box 4 of the present invention, wherein a third hollow plate 41 and a fourth hollow plate 42 are respectively arranged on the front and rear sides of the lower sand box 4; a third cleaning plate 43 is detachably installed on the outer side of the third hollow plate 41, and a second air inlet 44 is arranged on the third hollow plate 41 and the third cleaning plate 43, and the second air inlet 44 is connected to the cavity inside the third hollow plate 41, and a third vent hole 411 is arranged on the inner side of the third hollow plate 41, and one side of the third vent hole 411 is connected to the third hollow plate 4 1, and the other side of the third vent hole 411 is connected to the interior of the lower sand box 4; a fourth cleaning plate 45 is detachably installed on the outer side of the fourth hollow plate 42, and a fourth vent hole 421 is provided on the inner side of the fourth hollow plate 42. The fourth air hole is connected to the cavity inside the fourth hollow plate 42, and a second channel 422 is provided above the fourth hollow plate 42. The second channel 422 is connected to the cavity inside the fourth hollow plate 42, and the second channel 422 cooperates with the first channel 322.

[0024] like Figure 4-9As shown, a limiting member 5 is arranged on the lower side of the upper sand box 3 and the upper side of the lower sand box 4. The limiting member 5 on the upper sand box 3 and the limiting member 5 on the lower sand box 4 are arranged alternately and complementary. The limiting member 5 includes an angle member 51. A connecting portion 511 is arranged on the inner side of the angle member 51. Correspondingly, a slide groove 52 is arranged on the upper sand box 3 and the lower sand box 4. The slide groove 52 cooperates with the connecting portion 511. A threaded hole is arranged above the slide groove 52 and is connected with a connecting bolt 53. The connecting bolt 53 is slidably matched with the connecting portion 511. A spring 54 is arranged below the connecting portion 511 and the spring 54 is sleeved on the connecting bolt 53.

[0025] like Figure 3-10 As shown, the mold of the present invention also includes a filling mold 6, the material of the filling mold 6 is polystyrene foam (EPS), and the filling mold 6 includes a first filling layer 61, a second filling layer 62 and a third filling layer 63. The first filling layer 61, the second filling layer 62 and the third filling layer 63 are connected to each other, wherein the first filling layer 61 is located in the middle, and the second filling layer 62 and the third filling layer 63 are respectively located on both sides of the first filling layer 61. The first filling layer 61 includes a first connecting column 611, the second filling layer 62 includes a second connecting column 621, and the third filling layer 63 includes a third connecting column 631; the first connecting column 611, the second connecting column 621 and the third connecting column 631 are interconnected by a connecting rod 64; the two ends of the first connecting column 611 are respectively matched with the first air hole 311, the second air hole 321 or the third air hole 411, the fourth air hole 421, and the two ends of the second connecting column 621 and the third connecting column 631 are not matched with the air holes; it should be noted that during production, the number and size of each connecting column need to be reasonably adjusted according to the actual production to ensure the stability of the sand mold during the pouring process.

[0026] The principle of the present invention is: When the mold of the present invention is in use, the upper sand box 3 is placed on a molding machine (such as a shock-pressure molding machine), and the first mold 21 is placed on the molding machine at this time, and then the filling mold 6 is placed in the upper sand box 3. During the process, the two ends of the first filling layer 61 in the filling mold 6 are respectively matched with the first vent hole 311 and the second vent hole 321 (the length of the first connecting column 611 can be slightly larger than the width of the upper sand box 3. Since the filling mold 6 has a certain elastic deformation, the two ends of the first connecting column 611 are slightly inserted into the first vent hole 311 and the second vent hole 321). The filling mold 6 and the first mold 21 do not interfere with each other in space; after the filling mold 6 is installed, the operation of filling the molding sand can be carried out. It should be noted that since the material of the filling mold 6 is EPS, the breakage of the connecting rod 64 should be avoided as much as possible during the process to ensure the integrity of the filling mold 6.

[0027] After the upper sand box 3 is molded, the lower sand box 4 can be molded. The molding of the lower sand box 4 is consistent with that of the upper sand box 3, so it will not be repeated. After the upper and lower sand boxes 4 are molded, they can be closed after hardening and other steps. Before closing, a second mold 22, i.e., a sand core, is placed in the cavity formed by the mold.

[0028] At this point, the pouring operation can be carried out. During the pouring process, molten iron is poured into the mold along the pouring port (reserved during the molding process). During the process, the air in the mold is discharged through the exhaust holes (holes are punctured during the molding process, and damage to the filling mold 6 should be avoided as much as possible). When molten iron is seen at the pouring port, it means that the pouring is completed.

[0029] In traditional operation, after pouring is completed, when the brake disc 1 cools down slightly, the box is turned over to allow the brake disc 1 to cool in the air. In the implementation of the present invention, the heat generated during the pouring process causes the filling mold 6 in the upper and lower sand boxes 4 to melt, so after pouring is completed, a channel is formed inside the sand box. At this time, the air suction port 331 is connected to the induced draft fan, so that the outside air can be drawn to circulate from the inside of the sand box, thereby achieving cooling of the brake disc 1 in the sand box. During the process, due to the thermal insulation effect of the sand layer, the cooling rate of the brake disc 1 can be significantly reduced, and the cracking and deformation caused by the internal stress concentration of the brake disc 1 caused by the excessively fast cooling rate can be avoided, thereby significantly improving the quality of the brake disc 1.

[0030] In the embodiment of the present invention, air inlet holes are provided on the rear side of the upper flask 3 and the front side of the lower flask 4. By providing the air inlet holes on the rear side of the upper flask 3, the problem of gas temperature rising due to gas circulation when air is only taken in from the lower flask 4 can be avoided, which will lead to a large temperature difference between the upper flask 3 and the lower flask 4, thereby affecting the quality of the product. By taking in air from the rear side of the upper flask 3, fresh cooling air can be supplemented to eliminate the temperature difference. In addition, in the present embodiment, the number of the first air inlet holes 35 on the rear side of the upper flask 3 is less than the number of the second air inlet holes 44 on the front side of the lower flask 4 (the first air inlet holes 35 and the second air inlet holes 44 are of the same size and have a diameter of 5 mm, and the number of the first air inlet holes 35 is approximately half of the second air inlet holes 44), thereby avoiding excessive air from entering through the first air inlet holes 35, thereby resulting in a small amount of air intake into the second air inlet holes 44 and uneven temperatures between the upper and lower parts.

[0031] In the embodiment of the present invention, an induced draft fan can be connected to the air exhaust port 331. During the process, multiple pipes can be extended through the induced draft fan and respectively matched with multiple sand boxes after casting (an air valve is correspondingly arranged on each pipe). A filter is arranged at the front end of the induced draft fan, and the hot air extracted by the induced draft fan can be directly introduced into the water cooling tank.

[0032] In the embodiment of the present invention, the interior of each hollow plate can be cleaned by means of the cleaning plate on each hollow plate. During the process, since both ends of the first connecting column 611 are inserted into the vent holes, it is inevitable that a small amount of the molten material of the filling mold 6 will enter the cavity in the hollow plate. At the same time, it is also inevitable that a small amount of sand will enter the cavity during use. Therefore, it is necessary to clean it in time. When cleaning, open the cleaning plate and use high-pressure air cleaning or manual cleaning.

[0033] In an embodiment of the present invention, the upper sand box 3 and the lower sand box 4 are provided with mutually cooperating limit members 5. During the process, the limit members 5 can be retracted to avoid affecting the sand box shape and facilitate the alignment of the upper and lower sand boxes 4. At the same time, the corner members 51 are easy to replace and are convenient for use in actual production.

[0034] The present invention is not limited to the above-mentioned optimal implementation mode. Anyone can derive other various forms of products under the inspiration of the present invention. However, no matter what changes are made in the shape or structure, all technical solutions that are the same or similar to those of the present application fall within the protection scope of the present invention.

Claims

1. Brake disc sand box forming mold, characterized by: It includes a sand box, a brake disc mold (2) and a filling mold (6); The sand box comprises an upper sand box (3) and a lower sand box (4); The brake disc mold (2) comprises a first mold (21), a second mold (22) and a third mold (23); the first mold (21) cooperates with an upper sand box (3) and performs sand box molding on the upper sand box (3); the third mold (23) cooperates with a lower sand box (4) and performs sand box molding on the lower sand box (4); the second mold (22) is placed between the upper sand box (3) and the lower sand box (4) after molding; The material of the filling mold (6) is polystyrene foam. The filling mold (6) is matched with the upper sand box (3) and the lower sand box (4) respectively. The filling mold (6) does not interfere with the first mold (21) and the third mold (23) in space. The filling mold (6) is heated and melted during pouring, and forms gas passages in the upper flask (3) and the lower flask (4), respectively. Hollow plates are provided on both sides of the upper flask (3) and the lower flask (4), and vents are provided on the inner sides of the hollow plates. The vents cooperate with the filling mold (6), and after the filling mold (6) is melted, the vents are connected to the formed gas passages. The cast brake disc (1) is indirectly cooled by passing air into the formed gas channels.

2. The brake disc sand box forming mold according to claim 1, characterized in that: The gas passages formed in the upper sand box (3) and the lower sand box (4) are connected to each other.

3. The brake disc sand box forming mold according to claim 2, characterized in that: The upper sand box (3) is provided with a first hollow plate (31) at the front side, an air extraction port (331) is provided on the outer side of the first hollow plate (31), and a first vent hole (311) is provided on the inner side of the first hollow plate (31), and the air extraction port (331) and the first vent hole (311) are respectively connected to the cavity inside the first hollow plate (31); a second hollow plate (32) is provided at the rear side of the upper sand box (3), a first air inlet hole (35) is provided on the outer side of the second hollow plate (32), a second vent hole (321) is provided on the inner side of the second hollow plate (32), and a first channel (322) is provided on the lower side of the second hollow plate (32), and the first air inlet hole (35), the second vent hole (321) and the first channel (322) are respectively connected to the cavity inside the second hollow plate (32). a third hollow plate (41) is arranged at the front side of the lower flask (4), a second air inlet hole (44) is arranged at the outer side of the third hollow plate (41), a third air vent hole (411) is arranged at the inner side of the third hollow plate (41), and the second air inlet hole (44) and the third air vent hole (411) are respectively connected to the cavity inside the third hollow plate (41); a fourth hollow plate (42) is arranged at the rear side of the lower flask (4), a fourth air vent hole (421) is arranged at the inner side of the fourth hollow plate (42), a second channel (422) is arranged at the upper side of the fourth hollow plate (42), and the fourth air vent hole (421) and the second channel (422) are respectively connected to the cavity inside the fourth hollow plate (42); and the first channel (322) is connected to the second channel (422).

4. The brake disc sand box forming mold according to claim 3, characterized in that: The number of the first air inlet holes (35) is smaller than the number of the second air inlet holes (44).

5. The brake disc sand box forming mold according to claim 3, characterized in that: The first hollow plate (31), the second hollow plate (32), the third hollow plate (41) and the fourth hollow plate (42) are all detachably provided with cleaning plates, and the installation openings of the cleaning plates after removal are communicated with the cavities inside the hollow plates.

6. The brake disc sand box forming mold according to claim 3, characterized in that: The filling mold (6) comprises a first filling layer (61), in which a first connecting column (611) is arranged. When the filling mold (6) is placed, the two ends of the first connecting column (611) extend to the ventilation holes on the inner sides of the hollow plates on the front and rear sides of the upper sand box (3) or the lower sand box (4).

7. The brake disc sand box forming mold according to claim 6, characterized in that: A second filling layer (62) and a third filling layer (63) are respectively arranged on the upper and lower sides of the first filling layer (61); the gas passage formed after the second filling layer (62) and the third filling layer (63) are melted is not connected to the hollow plates on both sides of the upper sand box (3) or the lower sand box (4).

8. The brake disc sand box forming mold according to claim 1, characterized in that: The lower part of the upper sand box (3) and the upper part of the lower sand box (4) are provided with mutually staggered and complementary limiting members (5), and the limiting members (5) are elastically and telescopically connected to the box body of the upper sand box (3) or the lower sand box (4).

9. The brake disc sand box forming mold according to claim 8, characterized in that: The limiting member (5) comprises an angle member (51), the angle member (51) is slidably connected to the box body of the upper sand box (3) or the lower sand box (4), a connecting portion (511) is arranged on the inner side of the angle member (51), a slide groove (52) is arranged on the box body corresponding to the connecting portion (511), a connecting bolt (53) is installed in the slide groove (52) and passes through the connecting portion (511) from top to bottom, and a spring (54) is arranged below the connecting portion (511), and the spring (54) is sleeved on the connecting bolt (53).

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