Brake disc sand box forming die

Abstract

The present invention relates to the technical field of sand casting, and particularly to a sand box forming mold for a brake disc, which includes a sand box, a brake disc mold, and a filling mold. The sand box is shaped by the brake disc mold and the filling mold. The filling mold is made of polystyrene foam. During the casting process, the filling mold is heated and melted to form a gas channel inside the sand box. The gas channel is connected to the hollow plates on both sides of the sand box, and the hollow plates on both sides of the sand box are connected to the external atmosphere. Thus, under the condition of introducing air, indirect cooling of the brake disc cast in the sand box can be achieved. The present invention adopts the method of cooling the brake disc by introducing air into the sand box. On the one hand, during the process, it avoids the situation that the cooling speed is too fast when the brake disc after casting is directly cooled in the air, which affects the product quality. On the other hand, it also avoids the situation of long cooling time and affecting the product quality when cooling in the sand box. It plays a positive role in improving production efficiency and ensuring product quality.

Description

Technical Field

[0001] The present invention relates to the technical field of sand casting, and particularly to a sand box forming die for a brake disc. Background Art

[0002] The brake disc, also known as the brake rotor, is a friction couple on the disc brake and rotates with the wheel when the vehicle is moving forward; when the vehicle brakes, the caliper clamps the brake disc for friction braking to slow down or stop the vehicle; the quality of the brake disc plays a crucial role in driving safety.

[0003] Existing brake disc models and specifications vary, but the manufacturing process all adopts the casting method. During the process, molten iron is poured into the sand box die, and when the iron cools, the brake disc blank can be obtained, and then the brake disc product can be obtained after finishing.

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

[0005] Therefore, a sand box forming die for a brake disc that can coordinate the cooling speed and cooling time during the production process of the brake disc, so as to effectively guarantee the production efficiency while ensuring the product quality, is a technical problem that needs to be solved currently. Summary of the Invention

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

[0007] To achieve the above purpose, the present invention adopts the following technical scheme: A sand box forming die for a brake disc, comprising a sand box, a brake disc die, and a filling die;

[0008] The sand box includes an upper sand box and a lower sand box;

[0009] The described brake disc mold includes a first mold, a second mold, and a third mold. The first mold cooperates with the upper sand box to perform sand box molding on the upper sand box. The third mold cooperates with the lower sand box to perform sand box molding on the lower sand box. The second mold is placed between the molded upper sand box and the lower sand box.

[0010] The material of the described filling mold is polystyrene foam. The filling mold cooperates with the upper sand box and the lower sand box respectively, and does not interfere with the first mold and the third mold in space.

[0011] The filling mold is heated and melted during pouring to form gas channels in the upper sand box and the lower sand box respectively. Hollow plates are provided on both sides of the upper sand box and the lower sand box. Vent holes are provided on the inner side of the hollow plates. The vent holes cooperate with the filling mold. After the filling mold melts, the vent holes are connected to the formed gas channels.

[0012] By introducing air into the formed gas channels, indirect cooling is performed on the poured brake disc.

[0013] Further, the gas channels formed in the upper sand box and the lower sand box are interconnected.

[0014] Further, 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 vent hole is provided on the inner side of the first hollow plate. The air extraction port and the first vent hole 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 hole is provided on the outer side of the second hollow plate. A second vent hole is provided on the inner side of the second hollow plate. A first channel is provided on the lower side of the second hollow plate. The first air inlet hole, the second vent hole, and the first channel are respectively connected to the cavity inside the second hollow plate. A third hollow plate is provided on the front side of the lower sand box. A second air inlet hole is provided on the outer side of the third hollow plate. A third vent hole is provided on the inner side of the third hollow plate. The second air inlet hole and the third vent hole are respectively connected to the cavity inside the third hollow plate. A fourth hollow plate is provided on the rear side of the lower sand box. A fourth vent hole is provided on the inner side of the fourth hollow plate. A second channel is provided on the upper side of the fourth hollow plate. The fourth vent hole and the second channel are respectively connected to the cavity inside the fourth hollow plate. The first channel is connected to the second channel.

[0015] Further, the number of the first air inlet holes is less than the number of the second air inlet holes.

[0016] Further, cleaning plates are detachably provided on the first hollow plate, the second hollow plate, the third hollow plate, and the fourth hollow plate. The installation openings after the cleaning plates are removed are connected to the cavities inside the respective hollow plates.

[0017] Further, the filling mold includes a first filling layer, and a first connecting column is arranged in the first filling layer. When the filling mold is placed, both ends of the first connecting column respectively extend into the ventilation holes inside the hollow plates on the front and rear sides of the upper sand box or the lower sand box.

[0018] Further, 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 communicated with the hollow plates on both sides of the upper sand box or the lower sand box.

[0019] Further, limiting members that are mutually staggered and complementary are arranged below the upper sand box and above the lower sand box, and the limiting members are elastically and telescopically connected to the boxes of the upper sand box or the lower sand box.

[0020] Further, the limiting member includes an angle member, the angle member is slidably connected to the box of the upper sand box or the lower sand box, a connecting portion is arranged inside the angle member, a sliding groove is arranged on the box corresponding to the connecting portion, a connecting bolt is installed through the connecting portion from top to bottom in the sliding groove, and a spring is arranged below the connecting portion, and the spring is sleeved on the connecting bolt.

[0021] Advantages of the present invention:

[0022] 1. The present invention adopts a filling component made of polystyrene foam. On the one hand, the cost is relatively low during the process, which is convenient for application in production. On the other hand, the filling component made of this material is heated and melted during casting to form a gas channel. Since the filling component is located inside the sand mold during the process and has less direct contact with air, it can avoid pollutants generated by a large amount of combustion, effectively reduce the physical harm to operating personnel, and contribute to the maintenance of the workshop environment;

[0023] 2. Through the gas channel generated when the filling component melts, after connecting with air, the present invention can quickly take away the heat inside the sand mold. At the same time, due to the heat preservation effect of the sand mold, the cooling process of the casting can be effectively controlled, avoiding too fast or too slow cooling, which helps to ensure the quality of the product;

[0024] 3. By setting the first air inlet hole and the second air inlet hole and adjusting the distribution of the first air inlet hole and the second air inlet hole, when the brake disc casting is cooled, the cooling speeds of the upper and lower parts are kept relatively uniform, thus playing a positive role in improving the quality of the product. Description of the drawings

[0025] Figure 1 is a schematic diagram of the existing brake disc structure (top view);

[0026] Figure 2 is a schematic diagram of the existing brake disc structure (bottom view);

[0027] Figure 3 is a schematic structural diagram of an existing brake disc mold;

[0028] Figure 4 is a schematic structural diagram (front view) of the upper sand box of the present invention;

[0029] Figure 5 is a schematic structural diagram (rear view) of the upper sand box of the present invention;

[0030] Figure 6 is a schematic structural diagram of the upper sand box of the present invention (in the Figure 4 up and down flipping state);

[0031] Figure 7 is a schematic structural diagram (front view) of the lower sand box of the present invention;

[0032] Figure 8 is a schematic structural diagram (rear view) of the lower sand box of the present invention;

[0033] Figure 9 is the present invention Figure 7 schematic installation structure diagram of the limiting member after partial enlargement of part A in;

[0034] Figure 10 is a schematic structural diagram of the filling mold of the present invention.

[0035] Names corresponding to each mark in the figure:

[0036] 1. Brake disc; 11. Upper half part; 12. Middle part; 13. Lower half part; 2. Brake disc mold; 21. First mold; 22. Second mold; 23. Third mold; 3. Upper sand box; 31. First hollow plate; 311. First ventilation hole; 32. Second hollow plate; 321. Second ventilation 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. Third ventilation hole; 42. Fourth hollow plate; 421. Fourth ventilation hole; 422. Second channel; 43. Third cleaning plate; 44. Second air inlet hole; 45. Fourth cleaning plate; 5. Limiting member; 51. Corner member; 511. Connecting part; 52. Sliding 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 implementation manners

[0037] Next, the technical solutions of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention.

[0038] Embodiments of the present invention:

[0039] AsFigure 1-2 As shown in the figure, it is a schematic structural diagram of an existing brake disc 1. The figure shows a ventilated brake disc 1, which includes an upper half 11, a lower half 13, and an intermediate part 12 located between the upper half 11 and the lower half 13. The intermediate part 12 is fixedly connected to the upper half 11 and the lower half 13 respectively. Among them, the intermediate part 12 is an air duct.

[0040] As Figure 2-3 shown in the figure, it is an existing brake disc mold 2, which includes a first mold 21, a second mold 22, and a third mold 23. Among them, the first mold 21 is adapted to the upper half 11, the third mold 23 is adapted to the lower half 13, and the second mold 22 is adapted to the intermediate part 12; the second mold 22 is a sand core.

[0041] As Figure 4-6 shown in the figure, it is a schematic structural diagram of the upper sand box 3 of the present invention. 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. An air extraction port 331 is installed on the first cleaning plate 33, and the air extraction port 331 is communicated with the internal cavity of the first hollow plate 31. A first ventilation hole 311 is arranged on the inner side of the first hollow plate 31. One side of the first ventilation hole 311 is communicated with the internal cavity of the first hollow plate 31, and the other side of the first ventilation hole 311 is communicated with the inside of the upper sand box 3; a second cleaning plate 34 is detachably installed on the outer side of the second hollow plate 32. 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 communicated with the cavity inside the second hollow plate 32. A second ventilation hole 321 is arranged on the inner side of the second hollow plate 32. One side of the second ventilation hole 321 is communicated with the cavity inside the second hollow plate 32, and the other side of the second ventilation hole 321 is communicated with the inside of the upper sand box 3; a first channel 322 is arranged below the second hollow plate 32, and the first channel 322 is communicated with the cavity inside the second hollow plate 32.

[0042] As Figure 6-8As shown in the figure, it is a schematic structural diagram of the lower sand box 4 of the present invention. 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. Second air inlet holes 44 are provided on both the third hollow plate 41 and the third cleaning plate 43. The second air inlet holes 44 communicate with the cavity inside the third hollow plate 41. A third ventilation hole 411 is provided on the inner side of the third hollow plate 41. One side of the third ventilation hole 411 communicates with the cavity inside the third hollow plate 41, and the other side of the third ventilation hole 411 communicates with the inside of the lower sand box 4; a fourth cleaning plate 45 is detachably installed on the outer side of the fourth hollow plate 42. A fourth ventilation hole 421 is provided on the inner side of the fourth hollow plate 42. The fourth air hole communicates with the cavity inside the fourth hollow plate 42. A second channel 422 is provided above the fourth hollow plate 42. The second channel 422 communicates with the cavity inside the fourth hollow plate 42, and the second channel 422 cooperates with the first channel 322.

[0043] As Figure 4-9 shown, limit members 5 are provided on the lower side of the upper sand box 3 and the upper side periphery of the lower sand box 4. The limit members 5 on the upper sand box 3 and the limit members 5 on the lower sand box 4 are arranged in an alternating and complementary manner. The limit member 5 includes an angle member 51. A connecting portion 511 is provided inside the angle member 51. Corresponding chutes 52 are provided on the upper sand box 3 and the lower sand box 4. The chutes 52 cooperate with the connecting portion 511. A threaded hole is provided above the chute 52 and a connecting bolt 53 is connected. The connecting bolt 53 is slidably matched with the connecting portion 511. A spring 54 is provided below the connecting portion 511. The spring 54 is sleeved on the connecting bolt 53.

[0044] As Figure 3-10 shown, the mold of the present invention further includes a filling mold 6. The material of the filling mold 6 is polystyrene foam (EPS). 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. Among them, 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. 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 connected to each other through a connecting rod 64; both ends of the first connecting column 611 cooperate with the first ventilation hole 311, the second ventilation hole 321, or the third ventilation hole 411, the fourth ventilation hole 421 respectively. Both ends of the second connecting column 621 and the third connecting column 631 do not cooperate with each ventilation hole; 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.

[0045] The principle of the present invention is as follows:

[0046] 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). At this time, the first mold 21 is placed on the molding machine, and then the filling mold 6 is placed in the upper sand box 3. During the process, both ends of the first filling layer 61 in the filling mold 6 are respectively matched with the first ventilation hole 311 and the second ventilation hole 321 (the length of the first connecting column 611 can be slightly greater than the width of the upper sand box 3. Due to the certain elastic deformation of the filling mold 6, both ends of the first connecting column 611 are slightly inserted into the first ventilation hole 311 and the second ventilation hole 321), and there is no interference in space between the filling mold 6 and the first mold 21. After the filling mold 6 is installed, the operation of filling molding sand can be carried out. It should be noted during the process that since the material of the filling mold 6 is EPS, the fracture of the connecting rod 64 should be avoided as much as possible to ensure the integrity of the filling mold 6.

[0047] After the upper sand box 3 is molded, the lower sand box 4 can be molded at this time. The molding of the lower sand box 4 is the same as that of the upper sand box 3, so it will not be elaborated here. After the upper and lower sand boxes 4 are molded, the mold can be closed after steps such as hardening. Before closing the mold, the second mold 22, that is, the sand core, is placed in the cavity formed by the mold.

[0048] At this time, the pouring operation can be carried out. During the pouring process, the molten iron flows 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 punched 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 indicates that the pouring is completed.

[0049] In the traditional operation, after the pouring is completed, when the brake disc 1 is slightly cooled, the mold is turned over to let the brake disc 1 cool in the air. In the implementation of the present invention, the heat generated during the pouring process melts the filling mold 6 in the upper and lower sand boxes 4. Therefore, after the pouring is completed, a channel is formed inside the sand box. At this time, the air extraction port 331 is connected to an induced draft fan, so that the air outside can be pumped to flow through the inside of the sand box, thereby realizing the cooling of the brake disc 1 in the sand box. During the process, due to the heat preservation 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 stress concentration inside the brake disc 1 due to too fast cooling rate can be avoided, significantly improving the quality of the brake disc 1.

[0050] In the embodiment of the present invention, air inlets are provided on the rear side of the upper sand box 3 and the front side of the lower sand box 4. By providing an air inlet on the rear side of the upper sand box 3, it is possible to avoid the problem of the increase in gas temperature caused by gas circulation when only the lower sand box 4 intakes air, which will lead to a large temperature difference between the upper sand box 3 and the lower sand box 4, thus affecting the quality of the product. By the way of intaking air from the rear side of the upper sand box 3, fresh cooling air can be supplemented, and thus the temperature difference can be eliminated. In addition, in this embodiment, the number of the first air inlets 35 on the rear side of the upper sand box 3 is less than the number of the second air inlets 44 on the front side of the lower sand box 4 (the first air inlets 35 and the second air inlets 44 have the same size and dimension, with a diameter of 5 mm, and the number of the first air inlets 35 is about half of that of the second air inlets 44), so as to avoid too much air entering from the first air inlets 35, which will lead to less air intake of the second air inlets 44 and uneven upper and lower temperatures.

[0051] In the embodiment of the present invention, an induced draft fan can be connected to the air extraction port 331. During the process, multiple pipelines can extend from the induced draft fan and are respectively matched with multiple sand boxes after casting (air valves are correspondingly arranged on each pipeline), and 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.

[0052] In the embodiment of the present invention, through the cleaning plates on each hollow plate, the interior of each hollow plate can be cleaned. During the process, since both ends of the first connecting column 611 are inserted into the ventilation holes, it is inevitable that a small amount of the melt of the filling mold 6 will enter the cavity in the hollow plate, and at the same time, it is also inevitable that a small amount of sand grains will enter the cavity during use. Therefore, it is necessary to clean in time. When cleaning, open the cleaning plate, and it can be cleaned by high-pressure air sweeping or manual cleaning.

[0053] In the embodiment of the present invention, the limiting members 5 which are matched with each other are arranged on the upper sand box 3 and the lower sand box 4. During the process, the limiting members 5 can be telescopically arranged, so as to avoid affecting the sand box modeling, and at the same time, it is convenient for the upper and lower sand boxes 4 to be aligned. At the same time, the corner members 51 are convenient to replace and are convenient for use in actual production.

[0054] The present invention is not limited to the above best embodiment. Anyone can obtain other various forms of products under the inspiration of the present invention. However, no matter what changes are made in its shape or structure, as long as it has the technical solutions identical or similar to those of the present application, it falls within the protection scope of the present invention.

Claims

1. Brake disc sand box forming mold, characterized by: Including sand box, brake disc mold and 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 gas channels formed in the upper flask and the lower flask are connected with each other. A first hollow plate is arranged at the front side of the upper sand box, a second hollow plate is arranged at the rear side of the upper sand box, and a first air inlet hole is arranged on the outer side of the second hollow plate; a third hollow plate is arranged at the front side of the lower sand box, a second air inlet hole is arranged on the outer side of the third hollow plate, and a fourth hollow plate is arranged at the rear side of the lower sand box; the number of the first air inlet holes is less than the number of the second air inlet holes; a first channel is arranged at the lower side of the second hollow plate, and a second channel is arranged at the upper side of the fourth hollow plate, and the first channel is connected to the second channel; An air extraction port is provided on the outer side of the first hollow plate, and 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 air vent is provided on the inner side of the second hollow plate, and the first air inlet, the second air vent and the first channel are respectively connected to the cavity inside the second hollow plate; a third air vent is provided on the inner side of the third hollow plate, and the second air inlet and the third air vent are respectively connected to the cavity inside the third hollow plate; a fourth air vent is provided on the inner side of the fourth hollow plate, and the fourth air vent and the second channel are respectively connected to the cavity inside the fourth hollow plate; The cast brake disc is indirectly cooled by passing air into the formed gas channels; The lower part of the upper flask and the upper part of the lower flask are provided with mutually interlaced and complementary limiting parts, and the limiting parts are elastically and telescopically connected to the box body of the upper flask or the lower flask.

2. The brake disc sand box forming mold according to claim 1, characterized in that: 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.

3. The brake disc sand box forming mold according to claim 1, characterized in that: The filling mold comprises 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 vent holes inside the hollow plates at the front and rear sides of the upper sand box or the lower sand box respectively.

4. The brake disc sand box forming mold according to claim 3, characterized in that: The second filling layer and the third filling layer are respectively arranged on the upper and lower sides of the first filling layer, and the gas channels formed by melting the second filling layer and the third filling layer are not connected with the hollow plates on both sides of the upper sand box or the lower sand box.

5. The brake disc sand box forming mold according to claim 1, characterized in that: 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, and 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, and a spring is arranged below the connecting part, and the spring is sleeved on the connecting bolt.

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