A type of lower support casting mold

Abstract

This invention relates to the field of casting technology, and more particularly to a casting mold for a lower support, comprising a first mold and a second mold with vertical parting. The first mold is provided with a first pouring cup, a first upper riser, a first lower riser, a first upper casting mold, and a first lower casting mold. The first lower casting mold is offset below the first upper casting mold by 0.4-0.6 times the casting width from the center of the first mold. A flow divider unit is provided at the top of the first lower riser. The second mold is provided with a second pouring cup, a sprue, a second upper riser, and a second lower riser. The sprue is located below the second pouring cup and connected to it. After mold closing, the flow divider unit and the sprue are partially connected. This invention shortens the filling time difference between the upper and lower casting cavities, avoids casting problems such as cold shuts and shrinkage porosity, and ensures the structural strength and molding quality of the lower support casting.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a casting mold for a lower support. Background Technology

[0002] As a key load-bearing component of the vehicle structure, the lower support consists of a base plate and a set of connecting arms above. It needs to withstand alternating loads and impact stresses during vehicle operation, and has stringent requirements for the density, mechanical properties and dimensional consistency of the casting.

[0003] In existing vertical parting casting technology, the production of lower supports generally adopts a "one mold, two pieces" design: that is, only two casting molds are arranged in the horizontal direction within the same sand mold. This design has significant efficiency defects. The effective utilization area of ​​the sand mold is only 50%-60%, and a large amount of space is occupied by redundant sand. At the same time, the metal consumption of the gating system and risers accounts for 25%-30% of the total pouring volume, resulting in serious waste of raw materials. Moreover, only two products can be produced in a single pouring, and the production efficiency is far lower than the large-scale, batch production needs of the vehicle industry.

[0004] However, while improving efficiency through a single-mold, multi-part design can lead to serious quality problems due to the unique structure of the lower support. Traditional single-mold, multi-part casting systems lack targeted design for their gating systems, making it impossible to accurately distribute molten metal to the multiple cavities (e.g., four cavities) of the lower support casting structure. This results in a significant time difference between the filling of the upper and lower rows of casting cavities, sometimes reaching up to four seconds. Consequently, casting defects such as cold shuts and shrinkage porosity occur, ultimately leading to a substantial increase in the failure rate of the lower support castings and failing to meet the safety requirements for vehicle load-bearing components. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a lower support casting mold with a reasonable design that enables the production of multiple parts (such as four parts) from a single mold, thereby improving production efficiency. Furthermore, it ensures that the cavities of each casting are filled simultaneously, shortening the filling time difference, avoiding casting defects, and guaranteeing the quality of the castings.

[0006] The technical solution adopted by the present invention to solve its technical problem is: a lower support casting mold, a first mold and a second mold for vertical parting;

[0007] The first mold is provided with a first pouring cup, a first upper riser, a first lower riser, a first upper casting mold, and a first lower casting mold. The first lower casting mold is offset from the center of the first mold by 0.4-0.6 times the casting width and is located below the first upper casting mold. The first upper riser is located between two adjacent first upper casting molds, and each first upper casting mold is provided with a first upper riser. A first lower riser is provided between two adjacent first lower casting molds, and the first lower riser is connected to the two adjacent first lower casting molds respectively. A flow divider unit is provided at the top of the first lower riser.

[0008] The second mold is equipped with a second pouring cup corresponding to the first pouring cup, a vertical runner, a second upper riser corresponding to the first upper riser, and a second lower riser corresponding to the first lower riser. The vertical runner is located below the second pouring cup and connected to it. The second upper riser is connected to the vertical runner. After the mold is closed, the flow distribution unit and the vertical runner are partially connected, forming a connecting channel after the sand molds prepared by the first and second molds are closed. The molten metal from the vertical runner enters the flow distribution unit through this connecting channel, thereby entering the lower riser and realizing the pouring of the lower casting cavity. The staggered setting of the casting mold of the present invention not only facilitates the production of multiple castings from one mold, preferably four castings from one mold, in sand molds with limited dimensions, improving production efficiency, but also, the staggered design, combined with the absence of a horizontal runner, the direct supply filling method of the vertical runner, and the design of the upper and lower risers, effectively shortens the time difference of molten metal filling the upper and lower casting cavities, avoiding casting problems such as cold shuts and shrinkage.

[0009] Furthermore, the diversion unit has a square structure, with a width of 0.8-1.2 times the diameter of the first lower riser and a thickness of 0.3-0.6 times the diameter of the first lower riser. The structure of the diversion unit helps to control the flow rate and speed of the molten metal from the vertical gating channel into the lower riser, thus ensuring stable molten metal flow in the lower riser.

[0010] Furthermore, after mold closing, the area of ​​the connection between the flow divider unit and the vertical runner is equal to 0.5-0.8 times the area of ​​the connection between the first upper riser and the vertical runner. By the area relationship between the connection between the vertical runner, the flow divider, and the first upper riser, the size of the connection channel between the vertical runner, the upper riser, and the flow divider unit is limited, thereby ensuring the flow control of the molten metal in the vertical runner to the molten metal in the upper riser and the flow divider unit or the lower riser, and ensuring that the upper casting cavity and the lower casting cavity are filled simultaneously.

[0011] Furthermore, the centerlines of the diversion unit, the first lower riser, and the vertical runner are located in the same vertical plane, which is perpendicular to the first mold. The second upper riser is symmetrically located on both sides of the vertical runner. This facilitates the consistency of molten metal pouring and feeding between the upper and lower rows of castings, avoids casting defects such as cold shuts and shrinkage porosity, and improves casting quality.

[0012] Furthermore, the gates of the first upper row of casting molds and the first lower row of casting molds are respectively located above the connecting arm of the casting mold. The gates are flat, the length of the gates is 1 / 4 to 1 / 3 of the width of the casting mold, and the height of the gates is 1 / 4 to 1 / 3 of the height of the casting base.

[0013] Furthermore, during casting, the pouring temperature of the molten metal is 1450-1500℃, the pouring speed is 0.8-1.2 kg / s, and a stepped pouring method must be adopted during the pouring process.

[0014] Furthermore, the first upper row of casting molds and the first lower row of casting molds are provided with exhaust channels, through which gas inside the casting cavity can be discharged.

[0015] The beneficial effects of this invention are as follows: The casting mold of this invention does not have a horizontal sprue; the vertical sprue is directly connected to the pouring cup, avoiding the flow resistance and eddy current problems caused by the horizontal sprue. During pouring, the molten metal is guided through the vertical sprue to fill the upper and lower casting cavities. The amount of molten metal entering the upper and lower casting cavities is controlled by the flow distribution unit, shortening the filling time difference between the upper and lower casting cavities to less than 1.5 seconds. This ensures simultaneous filling and complete filling of the upper and lower casting cavities, thereby guaranteeing the quality of the lower support casting. Furthermore, the direct-supply filling design of the vertical sprue reduces filling pressure loss, which is beneficial for ensuring complete filling of the cavities. Simultaneously, the staggered design of the upper and lower castings and the molten metal flow control of the flow distribution unit reduce turbulence caused by liquid flow collision, optimizing the filling path of the molten metal during pouring. This invention shortens the filling time difference between the upper and lower rows of casting cavities, avoids casting problems such as cold shuts and shrinkage, and ensures the structural strength and molding quality of the lower support casting. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the first mold of the present invention.

[0017] Figure 2 This is a front view of the first mold of the present invention.

[0018] Figure 3 This is a schematic diagram of the structure of the second mold of the present invention.

[0019] Explanation of reference numerals in the attached figures:

[0020] 10 – First mold, 101 – First pouring cup, 102 – First upper riser, 103 – First lower riser, 104 – First upper casting mold, 105 – First lower casting mold, 106 – Diverting unit, 107 – Venting channel, 20 – Second mold, 201 – Second pouring cup, 202 – Vertical runner, 203 – Second upper riser, 204 – Second lower riser. Detailed Implementation

[0021] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the scope of the invention.

[0022] It should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the present invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] like Figure 1 , Figure 2 and Figure 3As shown, a lower support casting mold of this embodiment includes a first mold 10 and a second mold 20 with vertical parting. The first mold 10 is provided with a first pouring cup 101, a first upper riser 102, a first lower riser 103, a first upper casting mold 104, and a first lower casting mold 105. The two connecting arms of the first upper casting mold 104 and the first lower casting mold 105 are arranged horizontally from left to right. The first upper casting mold 104 and the first lower casting mold 105 include a base plate of the lower support and two connecting arm structures. The first upper riser 102 is located above the first lower riser 103, and the first lower casting mold 105 is offset from the first upper casting mold 104, that is, the position of the first lower casting mold 105 offset from the middle of the first mold 10 by 0.4-0.6 times the casting width is located at... Below the first upper row casting mold 104; the first upper row riser 102 is located between two adjacent first upper row casting molds 104, each first upper row casting mold 104 is provided with the first upper row riser 102, preferably there are two first upper row casting molds 104 and two first upper row risers 102, the two first upper row risers 102 are located between the two first upper row casting molds 104 and are respectively connected to the two first upper row casting molds 104; a first lower row riser 103 is provided between two adjacent first lower row casting molds 105, and the first lower row riser 103 is respectively connected to the two adjacent first lower row casting molds 105, the top of the first lower row riser 103 is provided with a diversion unit 106, the diversion unit 106 is connected to the casting cavity of the first lower row riser 103;

[0025] The second mold 20 is provided with a second pouring cup 201 corresponding to the first pouring cup 101, a vertical runner 202, a second upper riser 203 corresponding to the first upper riser 102, and a second lower riser 204 corresponding to the first lower riser 103. The second mold 20 is provided with a boss casting mold for forming the bottom boss of the lower support base plate. The boss casting mold is provided with corresponding connecting holes at the four corners of the first upper casting mold 104 and the first lower casting mold 105. The vertical runner 202 Located below and connected to the second pouring cup 201, the sidewall of the second upper riser 203 is connected to the vertical runner 202; after the mold is closed, the flow divider unit 106 and the vertical runner 202 overlap, that is, after the sand mold prepared by the first mold 10 and the second mold 20 is closed, the cavity of the flow divider unit 106 and the cavity of the vertical runner 202 are connected, that is, the molten metal in the vertical runner 202 is introduced into the first lower riser 103 through the flow divider unit 106.

[0026] During casting, sand molds are prepared using the first mold 10 and the second mold 20. After the sand molds are closed, a complete casting cavity is obtained. The first pouring cup 101 and the second pouring cup 201 form a funnel-shaped structure. When pouring molten metal, the funnel-shaped structure is designed to buffer the impact and reduce slag entrapment. The molten metal then enters the vertical runner 202 located below the second pouring cup 201. During pouring, the molten metal is poured from the wide end of the funnel-shaped structure. After being buffered by the inner wall of the funnel-shaped structure, the molten metal smoothly enters the vertical runner 202. Subsequently, guided by the vertical runner 202 and through the overlapping connection between the vertical runner 202 and the diversion unit 106, the flow rate of the molten metal at each connection point of the vertical runner 202 is controlled. This allows a portion of the molten metal to enter the upper casting cavity (including the first upper casting mold 104 and the second upper casting mold) through the connection channel between the vertical runner 202 and the second upper riser 203. One part enters the lower row of casting cavities (including the cavity formed by splicing the first lower row of casting molds 105 and the second lower row of casting molds) through the guide channel formed by the vertical gating 202 and the diversion unit 106; at the same time, the flow ratio of molten metal entering the upper and lower row of casting cavities is controlled by the structural design of the diversion unit 106, shortening the filling time difference between the upper and lower row of casting cavities, and finally realizing the simultaneous filling and filling of the upper and lower row of casting cavities, avoiding casting defects caused by asynchronous filling.

[0027] The diversion unit 106 has a square structure. The width of the diversion unit 106 is 0.8-1.2 times the diameter of the first lower riser 103, and the thickness is 0.3-0.6 times the diameter of the first lower riser 103. After mold closing, the area of ​​the connection between the diversion unit 106 and the vertical runner 202 is equal to 0.5-0.8 times the area of ​​the connection between the first upper riser 102 and the vertical runner 202. This facilitates precise control of the flow rate of molten metal from the vertical runner 202 into the lower riser. It avoids both excessively large cross-sections of the diversion unit 106 leading to excessively rapid filling of the lower casting cavity and excessively small cross-sections leading to delayed filling of the lower casting cavity. This ensures a stable flow of molten metal into the lower riser, thereby guaranteeing the casting quality of the lower casting cavity. Furthermore, it facilitates the coordinated distribution of molten metal flow between the upper and lower casting cavities, ensuring simultaneous filling and completion of both cavities. During the feeding process, the structure and size design of the diversion unit 106 also helps to ensure the flow of molten metal within the diversion unit 106, ensure the feeding of the lower castings, and reduce shrinkage defects in the lower castings.

[0028] The gating gates of the first upper row of casting molds 104 and the first lower row of casting molds 105 are respectively located above the connecting arms of the casting molds. The gating gates are flat, with a length of 1 / 4 to 1 / 3 of the width of the casting mold and a height of 1 / 4 to 1 / 3 of the height of the casting base. The design of the gating gate position, structure, and size facilitates the smooth diffusion and filling of the molten metal within the casting cavity, avoiding casting defects such as cold shuts and shrinkage porosity.

[0029] The centerlines of the diversion unit 106, the first lower riser 103, and the vertical runner 202 are located in the same vertical plane, which is perpendicular to the first mold 10. The second upper riser 203 is symmetrically located on both sides of the vertical runner 202. In this invention, the lower support casting adopts unilateral injection, and the upper and lower rows of castings are staggered. The centerlines of the diversion unit 106, the first lower riser 103, and the vertical runner 202 are coplanar, and this vertical plane is perpendicular to the first mold 10. This coplanar design of the centerlines ensures the symmetry of the flow of molten metal during the diversion process, so that the lower row of casting cavities on both sides receive a uniform supply of molten metal, reducing the difference in filling amount between the two sides of the casting cavity and reducing the difference in casting formation. At the same time, during the cooling and feeding process, this coplanar design of the centerlines helps to ensure the consistency of the feeding path of the upper and lower row of casting cavities, improves the feeding efficiency of the lower riser for the lower row of castings, and avoids defects such as shrinkage cavities or porosity in the casting due to the offset of the feeding path.

[0030] During casting, the pouring temperature of the molten metal is 1450-1500℃, and the pouring speed is 0.8-1.2 kg / s. A stepped pouring method must be adopted during the pouring process, that is, the speed of the first 1 / 3 of the pouring volume is 80% of the set speed, the speed of the middle 1 / 3 of the pouring volume is 100% of the set speed, and the speed of the last 1 / 3 of the pouring volume is 90% of the set speed. By coordinating the control of pouring temperature, speed and stepped pouring, the molten metal can be prevented from solidifying prematurely due to low temperature. At the same time, turbulence caused by excessive speed during the pouring process can be effectively avoided, thus ensuring the stability of the filling process.

[0031] The first upper row casting mold 104 and the first lower row casting mold 105 are provided with exhaust channels 107 to discharge the gas generated in the mold cavity during the pouring process, avoid porosity defects, and ensure the density of the casting.

[0032] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A casting mold for a lower support, characterized in that: Includes a first mold (10) and a second mold (20) for vertical parting; The first mold (10) is provided with a first pouring cup (101), a first upper riser (102), a first lower riser (103), a first upper casting mold (104), and a first lower casting mold (105). The first lower casting mold (105) is offset from the center of the first mold (10) by 0.4-0.6 times the casting width and is located below the first upper casting mold (104). The first upper riser (102) is located between two adjacent first upper casting molds (104), and each first upper casting mold (104) is provided with the first upper riser (102). A first lower riser (103) is provided between two adjacent first lower casting molds (105), and the first lower riser (103) is connected to the two adjacent first lower casting molds (105). A flow divider unit (106) is provided at the top of the first lower riser (103). The second mold (20) is provided with a second sprue cup (201) corresponding to the first sprue cup (101), a vertical runner (202), a second upper riser (203) corresponding to the first upper riser (102), and a second lower riser (204) corresponding to the first lower riser (103). The vertical runner (202) is located below the second sprue cup (201) and is connected to the second sprue cup (201). The second upper riser (203) is connected to the vertical runner (202). After the mold is closed, the flow distribution unit (106) and the vertical runner (202) are partially connected.

2. The lower support casting mold according to claim 1, characterized in that: The diversion unit (106) has a square structure. The width of the diversion unit (106) is 0.8-1.2 times the diameter of the first lower riser (103), and the thickness is 0.3-0.6 times the diameter of the first lower riser (103).

3. The lower support casting mold according to claim 1, characterized in that: After the mold is closed, the area of ​​the overlapping part of the flow distribution unit (106) and the vertical runner (202) is equal to 0.5-0.8 times the contact area between the first upper riser (102) and the vertical runner (202).

4. The lower support casting mold according to claim 1, characterized in that: The gates of the first upper row casting mold (104) and the first lower row casting mold (105) are located above the connecting arm of the casting mold. The gates are flat, the length of the gates is 1 / 4 to 1 / 3 of the width of the casting mold, and the height of the gates is 1 / 4 to 1 / 3 of the height of the casting base.

5. The lower support casting mold according to claim 1, characterized in that: The second upper riser (203) is symmetrically located on both sides of the vertical runner (202). The center lines of the flow divider unit (106), the first lower riser (103) and the vertical runner are located in the same vertical plane, which is perpendicular to the first mold (10).

6. The lower support casting mold according to claim 1, characterized in that: During casting, the temperature of the molten metal is 1450-1500℃, the casting speed is 0.8-1.2 kg / s, and a stepped casting method must be used during the casting process.

7. The lower support casting mold according to claim 1, characterized in that: The first upper row casting type (104) and the first lower row casting type (105) are provided with exhaust channels (107).

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