Ventilation type brake disc pouring system with high product yield

Abstract

The invention discloses a ventilation type brake disc pouring system with high yield, comprising: a sprue, the upper end of the sprue is provided with a pouring cup, and the lower end of the sprue is connected with a first cross gate; the second cross gate is fixed at one end of the first cross gate, and the inner side of the first cross gate is provided with a filtering piece for filtering the castable; a first shunt runner; the second flow dividing pouring gate and the first flow dividing pouring gate are arranged side by side; the filter seat is arranged between the first cross gate and the second cross gate, so that primary slag is effectively prevented from entering a subsequent pouring gate, meanwhile, turbulent molten iron generated by direct flushing of the straight gate is stabilized, and secondary oxidizing slag is reduced; in addition, molten iron is shunted at the first branch runner and the second branch runner, and flows in the multiple inner sprues to realize rapid mold filling, so that the molten iron is further purified, and the yield of the brake disc is greatly improved.

Description

Technical Field

[0001] The invention particularly relates to a ventilated brake disc casting system with high yield. Background Art

[0002] The automobile braking system can ensure the safety requirements of the vehicle during the braking process. The braking system includes brake discs, calipers, brackets, friction plates, retaining springs, etc. During the braking process of the automobile, the brake discs and friction plates rub against each other to generate braking torque to hinder the movement of the vehicle. The brake disc is made of gray cast iron. It is subjected to large normal and tangential forces during operation, and also bears a large thermal load. Therefore, the brake disc must have high strength, high wear resistance, high heat resistance and other properties to meet its braking requirements. Brake discs are divided into solid discs and ventilated discs. Ventilated discs have better heat dissipation performance, longer service life and better braking effect, so ventilated discs are mostly used on front brakes.

[0003] When casting existing ventilated brake discs, the casting material is directly injected into the inner side of the molding mold. The casting material flows quickly, which easily leads to the presence of gas in the cavity, causing slag hole defects in the brake disc after casting. The turbulent molten iron generated by direct current will also cause the generation of secondary oxidation slag, affecting the yield of the brake disc. For this reason, we propose a ventilated brake disc casting system with a high yield rate. Summary of the invention

[0004] The object of the present invention is to provide a ventilated brake disc casting system with a high yield rate to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a ventilated brake disc casting system with high yield, comprising:

[0006] A sprue, wherein the upper end of the sprue has a pouring cup, and the lower end of the sprue is connected to a first runner;

[0007] A second horizontal runner is fixed to one end of the first horizontal runner, and the first horizontal runner has a filter inside for filtering the castable;

[0008] The first branch runner;

[0009] A second diverter runner, wherein the second diverter runner is arranged side by side with the first diverter runner, and two ends of the second cross runner are respectively connected with the first diverter runner and the second diverter runner;

[0010] The forming mold is arranged on one side of the first diversion runner, and a plurality of feed ports connected with the first diversion runner are opened at the lower inner end of the forming mold.

[0011] Preferably, the first diversion runner is arc-shaped, and at least two inner gates are arranged on one side of the first diversion runner corresponding to the molding mold.

[0012] Preferably, the molding dies are arranged at two locations, and the other molding dies are arranged at one side of the second diversion runner and are connected with the inside of the second diversion runner.

[0013] Preferably, the inner gate is provided with one, and each inner gate corresponds to three feed ports of the molding die.

[0014] Preferably, the cross-sectional area ratio of the straight runner: the first horizontal runner: the second horizontal runner: [the first branch runner + the second branch runner]: [6*ingate] is 1:1.2:1.4:1.5:1.6-2.0.

[0015] Preferably, the cross-sectional areas of the six ingates are equal.

[0016] Preferably, the curvature of the inner gate matches the molding die, and the second branch runner is equal to the first branch runner in shape and size.

[0017] Preferably, the pouring cup is trumpet-shaped, and the sprue is perpendicular to the first runner.

[0018] Preferably, the filter material inside the filter element is foam.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] The present invention provides a filter seat between the first runner and the second runner, and arranges a foam filter in the filter seat, so as to effectively block the primary slag from entering the subsequent runner, and at the same time stabilize the turbulent molten iron generated by the straight runner, thereby reducing the generation of secondary oxidized slag; in addition, the molten iron is diverted at the first branch runner and the second branch runner, and the molten iron flows in multiple inner gates to achieve rapid filling, further purify the molten iron, and reduce the generation of oxidized slag; the first diversion runner is connected to the lower end of the inner side of the forming mold, so that the lower half of the friction surface of the brake disc can be filled with molten iron, and the molten iron fills the mold cavity from bottom to top, effectively discharges the gas in the mold cavity, reduces the risk of air entrapment during mold filling, and reduces the slag hole defects of the brake disc; in the present invention, no shrinkage feed risers are provided on the two forming molds, and each forming mold uses three inner gates to disperse the water inlet, so as to make full use of the self-shrinkage characteristics of secondary precipitation of graphite during the solidification of molten iron, effectively avoid internal shrinkage defects, and greatly improve the output rate of the brake disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of the present invention.

[0022] In the figure: 1. pouring cup; 2. straight runner; 3. first horizontal runner; 4. second horizontal runner; 5. first branch runner; 6. second branch runner; 7. inner gate; 8. filter element; 9. molding mold. DETAILED DESCRIPTION

[0023] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0024] See also Figure 1 The present invention provides a technical solution: a high-yield ventilated brake disc casting system, comprising:

[0025] A sprue 2, wherein the upper end of the sprue 2 is provided with a pouring cup 1, and the lower end of the sprue 2 is connected with a first horizontal runner 3;

[0026] The second runner 4 is fixed to one end of the first runner 3, and the first runner 3 has a filter 8 inside for filtering the castable;

[0027] The first branch runner 5;

[0028] A second diverter runner 6, wherein the second diverter runner 6 is arranged side by side with the first diverter runner 5, and both ends of the second cross runner 4 are respectively connected with the first diverter runner 5 and the second diverter runner 6;

[0029] The molding die 9 is disposed on one side of the first diversion runner 5 , and a plurality of feed ports communicating with the first diversion runner 5 are opened at the lower inner end of the molding die 9 .

[0030] Preferably, the first branch runner 5 is arc-shaped, and at least two inner gates 7 are arranged on one side of the first branch runner 5 corresponding to the molding die 9 .

[0031] Preferably, two molding dies 9 are provided, and another molding dies 9 is provided at one side of the second diversion runner 6 and communicated with the inside of the second diversion runner 6 .

[0032] Preferably, six ingates 7 are provided, and every three ingates 7 correspond to three feed ports of the molding die 9 respectively.

[0033] Preferably, the cross-sectional area ratio of the sprue 2: the first runner 3: the second runner 4: [the first branch runner 5+the second branch runner 6]: [6*the inner gate 7] is 1:1.2:1.4:1.5:1.6-2.0.

[0034] Preferably, the cross-sectional areas of the six ingates 7 are equal.

[0035] Preferably, the curvature of the inner gate 7 matches the molding die 9 , and the second branch runner 6 and the first branch runner 5 are equal in shape and size.

[0036] Preferably, the pouring cup 1 is trumpet-shaped, and the sprue 2 is perpendicular to the first runner 3 .

[0037] Preferably, the filter material inside the filter element 8 is foam.

[0038] Effect example:

[0039] The data of the ventilation disk in the specific embodiment of the present invention are as follows: the weight of the casting is 13.1 kg, the outer diameter is 350 mm, the height is 50 mm, the mold plate size is 800 mm*900 mm, and the upper and lower sand mold heights are both 250 mm; the pouring system is calculated as follows:

[0040] Runner calculation: Calculate the minimum cross-sectional area using the Ozan formula. Hydraulic formula for cross-sectional area resistance: S resistance = m / [ρTμ(2gHp) 1 / 2 ];

[0041] m—casting weight. The theoretical casting weight is calculated based on the product weight and expected yield rate, which is 13.1*2 / 0.80=32.8kg.

[0042] ρ—cast iron liquid phase density, taken as 0.007kg / cm 3 ;

[0043] T—pouring time, according to the formula G = m, μ' is 1.15-1.3 according to the experience of horizontal gray iron casting; μ' for fast filling is 1.15, calculated

[0044] μ—resistance coefficient. This process is a green sand process, and μ is 0.5;

[0045] Hp—pressure head height, Hp=Ho-P 2 / 2C, Ho-upper mold height, P-casting upper mold height, C-casting height, calculated Hp = 200-60 2 / 2*50=16.4cm (control the pouring liquid level at 200mm height of the upper mold);

[0046] The calculated S resistance is 32.8 / (0.007*6.6*0.5*(2*980*16.4)1 / 2)=7.92cm 2 =792mm 2 ;

[0047] Since the minimum area of ​​the pouring system is the sprue area, the sprue diameter is calculated to be 31.8 mm through S resistance. Considering the need for rapid filling, a 34 mm diameter sprue is selected.

[0048] To ensure the slag blocking effect, the runner ratio is straight runner 2: first horizontal runner 3: second horizontal runner 4: [first branch runner 5 + second branch runner 6]: [6* ingates 7] = 1.0: 1.2: 1.4: 1.5: 1.6-2.0; the cross-sectional areas of the six ingates 7 are equal. The total area of ​​the first horizontal runner 3 is determined to be 1089mm 2 The total area of ​​the second runner 4 is 1270mm 2 The total area of ​​the first branch runner 5 + the second branch runner 6 is 1361mm 2 The total area of ​​the six gates 7 is 1633mm 2 .

[0049] The present invention proposes a high-yield ventilated brake disc casting system, which provides a filter element 8 between a first horizontal runner 3 and a second horizontal runner 4, and arranges a foam filter sheet in the filter element 8, so as to effectively block primary slag from entering subsequent runners, and at the same time stabilize the turbulent molten iron generated by the straight runner 2, thereby reducing the generation of secondary oxidation slag; the present invention diverts the molten iron at the second horizontal runner, and the molten iron is quickly filled at the first diversion runner 5 and the second diversion runner 6, so as to further purify the molten iron. The present invention allows water to enter the lower half of the friction surface of the brake disc, and the molten iron fills the cavity from bottom to top, effectively discharging the gas in the cavity, reducing the risk of air entrapment during mold filling, and reducing the slag hole defects of the brake disc; the two products of the present invention use a riser-free shrinkage compensation process, fully utilizing the characteristics of secondary expansion and shrinkage compensation of graphite precipitation during the solidification of molten iron, effectively avoiding internal shrinkage defects, and achieving a brake disc yield rate of 80%. Small batch inspection and batch production sampling were performed through X-rays, and no shrinkage defects were found. After following up on subsequent machining, good feedback was obtained, no abnormal state occurred, and the process feasibility was excellent.

[0050] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high yield ventilated brake disc casting system, characterized in that: include: A sprue (2), wherein the upper end of the sprue (2) is provided with a pouring cup (1), and the lower end of the sprue (2) is connected to a first cross runner (3); A second horizontal runner (4) is fixed to one end of the first horizontal runner (3), and the first horizontal runner (3) has a filter (8) inside for filtering the castable material; A first diversion runner (5); A second diverter runner (6), wherein the second diverter runner (6) and the first diverter runner (5) are arranged side by side, and both ends of the second cross runner (4) are respectively connected to the first diverter runner (5) and the second diverter runner (6); The molding die (9) is arranged on one side of the first diversion runner (5), and a plurality of feed ports connected to the first diversion runner (5) are provided at the lower inner end of the molding die (9).

2. A high yield ventilated brake disc casting system according to claim 1, characterized in that: The first branch runner (5) is arc-shaped, and at least two inner gates (7) are arranged on one side of the first branch runner (5) corresponding to the molding mold (9).

3. A high yield ventilated brake disc casting system according to claim 2, characterized in that: The molding die (9) is provided at two locations, and the other molding die (9) is provided at one side of the second diverter runner (6) and is connected to the inside of the second diverter runner (6).

4. A high yield ventilated brake disc casting system according to claim 3, characterized in that: Six ingates (7) are provided, and every three ingates (7) correspond to three feed ports of the molding die (9).

5. A high yield ventilated brake disc casting system according to claim 4, characterized in that: The cross-sectional area ratio of the straight runner (2): the first horizontal runner (3): the second horizontal runner (4): [the first branch runner (5) + the second branch runner (6)]: [6* the inner gate (7)] is 1:1.2:1.4:1.5:1.6-2.

0.

6. A high yield ventilated brake disc casting system according to claim 4, characterized in that: The cross-sectional areas of the six ingates (7) are equal.

7. A high yield ventilated brake disc casting system according to claim 2, characterized in that: The curvature of the inner gate (7) matches the molding die (9), and the second branch runner (6) and the first branch runner (5) are equal in shape and size.

8. A high yield ventilated brake disc casting system according to claim 1, characterized in that: The pouring cup (1) is trumpet-shaped, and the sprue (2) is perpendicular to the first runner (3).

9. A high yield ventilated brake disc casting system according to claim 1, characterized in that: The filtering material inside the filter element (8) is foam.

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