Slag-shielding slow-flow pouring system and pouring mold with same

Abstract

The invention relates to the field of brake caliper pouring equipment, in particular to a slag-shielding slow-flow pouring system and a pouring mold with the same, and the slag-shielding slow-flow pouring system comprises a pouring gate unit, an outer pouring unit and an inner pouring unit; the sprue unit is connected with the ingate unit through the ingate unit; the sprue unit comprises a sprue cup; the outer pouring unit comprises a sprue; the inner pouring unit comprises a riser and an inner pouring gate; the straight pouring gate is connected with the inner pouring gate through a dead head; the liquid inlet ends and the liquid outlet ends of the risers are distributed in a staggered manner; through cooperative use of the sprue cup, the slag-avoiding cross gate, the sprue, the slow-flow cross gate and the dead head, the kinetic energy generated when molten metal impacts the cavity wall can be well reduced, sand holes, air holes and other derivative defects are reduced, the casting cleaning workload is reduced by 30%, and the production efficiency is improved by 20%.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of brake caliper pouring equipment, in particular to a slag shielding and slow flow pouring system and a pouring mold with the pouring system. BACKGROUND

[0002] In the production of metal castings, especially automotive safety components (such as brake caliper body supports) with high requirements for internal purity, mechanical properties and dimensional accuracy, the design of the pouring system is crucial.

[0003] Its core task is to guide the molten metal into the casting cavity smoothly and cleanly.

[0004] Traditional pouring systems are usually composed of basic units such as sprue cups, straight runners, cross runners, and ingates connected in series, but in actual application, due to limitations in design concepts or structural details, it is difficult to simultaneously achieve the two goals of "smooth filling" and "high-efficiency slag removal", resulting in low casting yield and unstable quality.

[0005] The existing technology mainly has the following shortcomings: first, the traditional pouring system often lacks systematic and gradient control of the flow state of the metal liquid.

[0006] After the metal liquid falls from the ladle, it continues to accelerate in the straight runner under the action of gravity, and still has a high kinetic energy when it reaches the cavity, which is easy to produce jetting and turbulence, thereby washing the cavity or the sand core, causing sand eye defects and entraining gas to form pores.

[0007] Secondly, in terms of slag (oxides, inclusions) removal, traditional designs rely on simple dross in the sprue cup or sedimentation in the cross runner, and the slag blocking means is single and limited in efficiency. For suspended slag moving with the liquid flow, especially for suspended slag with similar density to the metal liquid, there is a lack of effective active separation mechanism, which makes the slag easily enter the cavity, causing casting slag defects.

[0008] Traditional pouring systems often use single-point or asymmetric pouring methods; the traditional method is easy to cause asynchronous filling of the cavity, low temperature of the metal liquid at the far end, and thus cause poor filling, cold shut, shrinkage, and casting deformation and residual stress caused by non-uniform cooling and shrinkage, affecting the dimensional accuracy and service reliability of the casting.

[0009] The present CN 202639227 U discloses a pouring system for an automotive brake caliper shell on a vertical parting molding line, but the patent does not explicitly disclose a technical solution to solve the above technical problems.

[0010] Therefore, in order to improve or solve at least one of the above technical problems, it is necessary to improve the existing pouring system of the caliper body support. SUMMARY

[0011] The present application aims to provide a casting system which can layer drainage and slag shielding.

[0012] In order to achieve the above-mentioned purpose, the technical scheme adopted by the present application is as follows: A slag shielding and flow slowing casting system comprises a sprue unit, an outer pouring unit and an inner pouring unit. The sprue unit is connected with the outer pouring unit and the inner pouring unit. The sprue unit comprises a sprue cup. The outer pouring unit comprises a straight runner, and the inner pouring unit comprises a riser and an inner runner. The straight runner is connected with the inner runner through the riser. The liquid inlet end and the liquid outlet end of the riser are distributed in a staggered manner.

[0013] The outer pouring unit comprises two straight runners, the sprue cup is connected with the two straight runners through a slag shielding cross runner, at least one set of inner pouring units is arranged on each straight runner, and the inner pouring units on the two straight runners are distributed in a facing manner.

[0014] The slag shielding cross runner comprises a middle cross runner, the middle cross runner is connected with the straight runners through an end cross runner at each end, and the horizontal cross-sectional area of the middle cross runner is larger than that of the end cross runner.

[0015] The inner pouring unit further comprises a flow slowing cross runner, and the straight runner is connected with the riser through the flow slowing cross runner. The flow slowing cross runner is arranged at the end of the riser away from the sprue cup.

[0016] The riser is in the shape of a conical frustum, the end of the riser with a larger horizontal cross-sectional area is arranged close to the flow slowing cross runner, the flow slowing cross runner leads to the bottom of the riser, and the riser is communicated with the mold cavity of the casting through the inner runner.

[0017] The vertical cross section of the straight runner is in the shape of a conical frustum.

[0018] The straight runner comprises a tapered flat runner and a flow-through runner, the flow-through runner comprises a plurality of straight flow runners and a lapping runner, the adjacent straight flow runners are communicated through the lapping runner, the lapping runner is lapped on one straight flow runner at each end, and the tapered flat runner is connected with the adjacent straight flow runner.

[0019] The end of the flow slowing cross runner at the end of the straight runner away from the sprue cup is in an arc shape, and at least one inner pouring unit is connected to each straight flow runner.

[0020] The sprue cup is in the shape of a ladder, the sprue cup comprises an upper cup runner and a lower cup runner, the upper cup runner and the lower cup runner are both in the shape of an inverted conical frustum, and the minimum inner diameter of the upper cup runner is not less than the maximum inner diameter of the lower cup runner.

[0021] A pouring mold for brake caliper body support comprises a mold body, a support cavity and a pouring system are arranged in the mold body; each support cavity is communicated with an inner gate in one pouring system.

[0022] The present application has the advantages of: The application discloses a slag shielding and slow flow pouring system and a pouring mold with the pouring system.

[0023] The pouring system disclosed by the present application is communicated through the middle part of the riser, the riser can play a good feeding effect, and simultaneously, the riser plays a slow flow effect, so as to reduce the liquid flow rate entering the mold cavity; when the riser is used, liquid enters from the lower end and liquid exits from the side, so that the riser plays a role of a slow flow cabin.

[0024] Meanwhile, the pouring cup, the slag avoiding cross gate, the straight gate, the slow flow cross gate and the riser are used in cooperation, so that the kinetic energy of the metal liquid impacting the cavity wall can be well reduced, the derived defects such as sand holes and pores are reduced, the cleaning workload of the casting is reduced by 30%, and the production efficiency is improved by 20%.

[0025] In addition, the taper frustum riser design is adopted, so that the storage amount of the metal liquid can be reduced, and then the use cost of the metal liquid can be reduced to a certain extent.

[0026] The straight gate adopts a segmented staggered lap joint design, so that slag can be better blocked and impurities can be removed, and the casting quality can be improved.

[0027] The pouring system disclosed by the present application has excellent slag shielding (blocking) effect: in the present application, the pouring cup (floating up) → the slag avoiding cross gate (floating up) → the staggered lap joint straight gate (dynamic filtering) → the slow flow riser (floating up) can be formed, and a four-layer filtering net is formed.

[0028] The segmented staggered lap joint structure of the straight gate actively captures impurities by changing the flow direction, and is a high-efficiency passive filtering device.

[0029] The riser acts as a "slow flow cabin", and through the path of "entering from the bottom, exiting from the side and overflowing after rising", the high-speed liquid flow is "calmed"; the scouring of the mold cavity wall is greatly reduced, and the sand holes caused by sand scouring and the pores caused by turbulent gas are reduced.

[0030] The cleaning workload of the casting is reduced by 30%: the defects such as sand holes and burrs (caused by sand scouring) are reduced.

[0031] The production efficiency is improved by 20%: the waste rate is reduced, the rework is reduced, and the production rhythm and the qualification rate are naturally improved.

[0032] The conical frustum-shaped riser is smaller than a cylindrical riser with the same volume, and reduces the riser metal consumption in the process yield.

[0033] The stepped inverted-cone gate cup realizes initial buffering and slag blocking with a simple structure.

[0034] The variable cross-section slag-avoiding horizontal gate promotes impurity settlement by using the fluid mechanics principle (Bernoulli equation, large cross-section, slow flow speed).

[0035] The misaligned overlapping straight gate forms an active slag-blocking structure.

[0036] The slag-blocking and flow-reducing pouring system disclosed by the application is a very systematic and precise casting solution. BRIEF DESCRIPTION OF DRAWINGS

[0037] The following is a brief description of the content expressed by each drawing in the specification of the application and the marks in the drawings: Figure 1 It is a front view of the pouring system of the application.

[0038] Figure 2 It is a perspective view of the pouring system of the application.

[0039] The marks in the above drawings are as follows: 1, gate cup, 2, support cavity, 3, straight gate, 4, inner pouring unit. DETAILED DESCRIPTION

[0040] The following describes an optimal embodiment with reference to the drawings, to further explain the specific embodiments of the application in detail.

[0041] A slag-blocking and flow-reducing pouring system includes a gate unit, an outer pouring unit, and an inner pouring unit 4; the gate unit is connected to the inner pouring unit 4 through the outer pouring unit; the gate unit includes a gate cup 1; the outer pouring unit includes a straight gate 3; the inner pouring unit 4 includes a riser 42 and an inner gate 43; the straight gate 3 is connected to the inner gate 43 through the riser 42; the liquid inlet end and the liquid outlet end of the riser 42 are distributed in a staggered manner; the pouring system disclosed by the application is connected through the middle part of the riser 42, which can play a good feeding effect, and the riser 42 also plays a flow-reducing role to reduce the liquid flow rate into the casting cavity; when the riser 42 is used, the lower end is liquid-in and the side is liquid-out, so that the riser 42 acts as a flow-reducing chamber.

[0042] The disclosed sprue unit is responsible for receiving the liquid metal from the ladle, buffering and slag separation in the first step.

[0043] The outer sprue unit is responsible for guiding and distributing the channel; it is responsible for smoothly transporting the metal liquid to each inner sprue unit 4, and possibly performing secondary slag blocking.

[0044] The inner sprue unit 4 is the last stage of the system, responsible for reducing the kinetic energy of the metal liquid to the minimum and smoothly guiding it into the mold cavity, while also serving as a feeding function.

[0045] The sprue cup 1 mainly includes a sprue cup 1; the sprue cup 1 is usually inverted conical or basin-shaped; the sprue cup 1 is used to contain the initially poured metal liquid to avoid splashing and direct impact.

[0046] The sprue cup 1 of the present application is an inverted conical structure, which can expand the liquid surface area and reduce the flow rate, so that the molten slag and oxides with smaller density have enough time to float and stay at the top of the sprue cup 1.

[0047] The outer sprue unit mainly includes a straight runner 3; the straight runner 3 is a vertical channel; the height difference of the metal liquid column provides the necessary static pressure for the entire filling process; the metal liquid is guided from the sprue cup 1 to the lower inner sprue unit 4.

[0048] The riser 42 serves as a "slow-flowing cabin" and "settling cabin": the metal liquid enters from the bottom of the riser 42 from the straight runner 3 (or through the slow-flowing cross runner 41). Due to the lateral displacement of the outlet (inner runner 43), the metal liquid cannot flow directly out, but must first rise and turn inside the riser 42; this process converts a large amount of kinetic energy of the high-speed liquid flow into potential energy (liquid surface height), and the flow rate decreases.

[0049] In the relatively spacious and calm space of the riser 42, the metal liquid flow rate is extremely low, providing the last opportunity for the remaining small molten slag and bubbles to float. The light impurities float to the top of the riser 42, and the clean metal liquid flows out from the lower inner runner 43.

[0050] When the casting solidifies, the hot metal liquid stored in the riser 42 can effectively feed the casting to prevent shrinkage and porosity.

[0051] The inner runner 43 is the final passageway for the clean metal liquid after purification and speed reduction to enter the mold cavity.

[0052] Usually, a flat and dispersed design is adopted to further reduce the flow rate, so that the metal liquid fills the mold cavity smoothly, avoiding spraying and flushing.

[0053] The pouring system disclosed in the application realizes low-speed and stable mold filling by gradually consuming kinetic energy of the metal liquid through multiple means such as the enlarged cross section of the sprue cup 1, the shape control of the runner 3, and the volume buffering of the riser 42.

[0054] Based on Stokes law and density difference, the "full-range slag shielding" creates necessary conditions for slag floating or staying, such as lower flow rate, longer residence time, and collision point changing flow direction, which systematically solves the slag inclusion problem.

[0055] In the application, the outer pouring unit includes two runners 3; the sprue cup 1 is connected with the two runners 3 through the slag-avoiding cross runner 2; at least one group of inner pouring units 4 is arranged on each runner 3; the inner pouring units 4 on the two runners 3 are oppositely distributed; the sprue cup 1 is simultaneously divided into two runners 3 through the slag-avoiding cross runner 2; liquid can be supplied to two relatively independent areas or both sides of a large casting; each runner 3 is responsible for at least one group of inner pouring units 4 (a group usually includes a slow-flow cross runner 41, a riser 42, and an inner runner 43).

[0056] The inner pouring units 4 on the two runners 3 are oppositely distributed; finally, the metal liquid is introduced from the left and right or symmetrically opposite positions of the casting cavity.

[0057] The slag-avoiding cross runner 2 is the main channel connecting the sprue cup 1 and the two runners 3.

[0058] The slag-avoiding cross runner 2 mainly realizes core flow division and secondary slag blocking hub; the cross runner usually has a large horizontal projection area, and when the metal liquid flows from the sprue cup 1, the flow rate will be significantly reduced due to the enlarged cross section.

[0059] The flow division stably and uniformly distributes a stream of metal liquid to the two runners 3.

[0060] Through the arrangement of the two runners 3, the application can realize symmetric filling of the casting and reduce thermal stress: the metal liquid starts to fill from the opposite positions of the casting cavity at the same time and in equal amounts (in an ideal state). This avoids the problem of rapid cooling at the far end and insufficient filling pressure caused by unilateral filling, makes the solidification of each part of the casting more synchronous, and greatly reduces the risk of deformation, cold shut, and shrinkage.

[0061] Compared with single-point pouring, double-point symmetric pouring shortens the flow distance of the metal liquid to the farthest end of the cavity by nearly half, which helps to complete the mold filling before the temperature of the metal liquid drops too much, especially for thin-walled castings.

[0062] The inner sprue 43 disperses the metal liquid flow, the flow rate and flow of each inner sprue 43 outlet are smaller, and the local scouring of the sand core of the mold cavity is further reduced, and the sand hole defect is reduced.

[0063] Further, in the application, the slag-avoiding cross sprue 2 comprises a middle cross sprue 21; the two ends of the middle cross sprue 21 are connected with the straight sprue 3 through an end cross sprue 22 respectively; the horizontal sectional area of the middle cross sprue 21 is larger than that of the end cross sprue 22; in the application, the middle cross sprue 21 is connected below the sprue cup 1, the end cross sprue 22 plays a good role in lateral connection and communication; the transverse size of the middle cross sprue 21 is larger, and the transverse size of the end cross sprue 22 is smaller; the low-speed and stable environment of the middle cross sprue 21 greatly reduces the entrainment of impurities by turbulence; the larger middle cross section is like an “energy storage pool” or “pressure stabilizer”, which can absorb the instantaneous flow fluctuation from the sprue cup 1, so that the metal liquid flow to the two straight sprues 3 is more uniform and stable; the slag-avoiding cross sprue 2 with a large middle cross section and small two-end cross sections actively creates a low-speed settling zone, and solves the problem of heavy inclusion removal with high pertinence, while the stability of flow and the uniformity of distribution are considered.

[0064] In the application, the inner sprue unit 4 further comprises a slow-flow cross sprue 41; the straight sprue 3 is connected with the riser 42 through the slow-flow cross sprue 41; the slow-flow cross sprue 41 is arranged at the end of the riser 42 away from the sprue cup 1; the slow-flow cross sprue 41 of the application is arranged at the lower end of the riser 42, based on this design, the flow of the metal liquid in the riser 42 must follow the principle of “first rising and then overflowing”; the above design has the following effects: realizing ultimate “slow flow” and maximizing kinetic energy dissipation; when the metal liquid enters the riser 42 from the slow-flow cross sprue 41 at the bottom, the kinetic energy (mainly from the gravity acceleration of the straight sprue 3) carried by the metal liquid must overcome the work done by gravity to lift the liquid level in the entire riser 42 upward. This process converts a large amount of kinetic energy into potential energy.

[0065] When the metal liquid first enters the inside of the riser 42 and then flows out from the inner sprue 43, the flow rate of the metal liquid is obviously reduced, ensuring that the metal liquid entering the mold cavity is stable and slow, and fundamentally eliminating the pores and sand hole defects caused by the filling impact.

[0066] The metal liquid enters from the bottom of the riser 42, and in the long process of flowing upward, the flow rate is extremely slow and the direction is stable; this provides a separation environment for the impurities remaining in the metal liquid: light slag and bubbles: flow upward, and finally gather at the top of the riser 42; the riser 42 thus becomes an extremely efficient flotation and sedimentation separator.

[0067] In addition, the present application requires that the sprue 3 is connected with the riser 42 through the slow-flowing runner 41, and the runner is located at the distal end (bottom) of the riser 42; based on such a design, the last active kinetic energy dissipation of the system can be completed by forcibly changing the flow direction (vertically to horizontally and then vertically upward); it creates a bottom injection condition, ensures that an ideal laminar flow, temperature field and impurity separation environment can be formed inside the riser 42; this makes the entire inner pouring unit 4 from a passive "flow channel-container" combination, sublimates into an active and powerful "metal liquid final processor", which is one of the core designs to ensure that the castings obtain excellent internal and surface quality.

[0068] Further, in the present application, the riser 42 is in the shape of a truncated cone; the larger horizontal cross-section of the riser 42 is arranged close to the slow-flowing runner 41; the slow-flowing runner 41 leads to the bottom of the riser 42, and the riser 42 is communicated with the casting cavity through the inner runner 43; the riser 42 is large at the top and small at the bottom, like an inverted funnel; the slow-flowing runner 41 is connected at the bottom of the large end, and the inner runner 43 is connected at the side of the riser 42: the metal liquid enters from the wide bottom center, must fill the internal volume of the riser 42 upward, and then flows out from the side of the riser 42; ultimate slow flow and kinetic energy dissipation can be achieved; when the metal liquid enters the spacious bottom of the riser 42 from the bottom runner, "sudden expansion" occurs, and the flow rate decreases. Subsequently, the liquid flow needs to move upward to lift the liquid level in the entire riser 42, which converts most of the remaining kinetic energy into potential energy (liquid level height).

[0069] When subsequently flowing out from the side of the riser 42, the flow rate of the metal liquid is also relatively reduced, which is beneficial to eliminate defects such as gas entrapment and sand flushing caused by high-speed filling.

[0070] The truncated cone shape combined with bottom liquid injection makes the riser 42 become a high-efficiency "flotation-sedimentation combined separator" to complete the final purification of the metal liquid.

[0071] The high-temperature metal liquid is injected from the bottom of the riser 42, naturally forming an ideal temperature gradient with hot bottom and relatively cold top. This ensures that the riser 42 is the last to solidify during the solidification process of the casting, the feeding channel remains unobstructed, and the feeding pressure is large; significantly improves the feeding capacity of the casting, effectively prevents shrinkage and porosity defects, and improves the density of the casting.

[0072] In the present application, the vertical section of the sprue 3 is frustum-shaped; in the sprue 3, the metal liquid accelerates downward under the action of gravity. If the sprue 3 is a cylinder with equal cross sections from top to bottom, the flow rate will continuously increase along the height, resulting in a very high flow rate at the bottom, a large impact force, and easy conversion into severe turbulence and splashing at the bottom; the inside of the sprue 3 can not be able to maintain full filling, forming a "non-full flow", thereby entraining air, causing oxidation and slag inclusion; the sprue 3 of the present application is designed to be large at the top and small at the bottom, so that the change trend of its cross-sectional area matches the flow rate increase trend caused by gravitational acceleration; effectively preventing air from being sucked into the metal liquid flow, which is the first line of defense to reduce casting porosity defects.

[0073] The frustum-shaped design partially offsets the effect of gravitational acceleration by gradually narrowing the flow channel, making the flow rate increase from the top to the bottom more gentle and controllable; providing a relatively stable "incoming flow" for the slow-flowing cross runner 41 downstream of the metal liquid, avoiding the violent impact of high-speed liquid flow on the cross runner, and being conducive to subsequent settling and flow stabilization.

[0074] The bottom (small end) of the frustum-shaped is usually connected with an arc-shaped transition section or a sprue nest. This design from large to small combined with an arc shape can make the metal liquid more smoothly change from vertical downward flow to horizontal flow, greatly reducing the vortex, energy loss and scouring of the sand caused by sharp turns.

[0075] Further, in the present application, the sprue 3 includes a tapered flat flow channel 31 and a flow-through runner 32; the flow-through runner 32 includes a plurality of straight runners 321 and a lap joint runner 322; adjacent straight runners 321 are connected through the lap joint runner 322; the lap joint runner 322 is lap-jointed on one straight runner 321 at both ends; the tapered flat flow channel 31 is connected with adjacent straight runners 321; the tapered flat flow channel 31 is located at the upper part of the sprue 3 and receives the metal liquid from the cross runner; the "flat" shape can increase the resistance, playing the role of initial flow stabilization and distribution.

[0076] The flow-through runner 32 includes a plurality of vertical straight runners 321 and lap joint runners 322; the straight runners 321 and the lap joint runners 322 are alternately connected, so that the flow-through runner 32 forms a labyrinth structure, which is conducive to the separation of impurities.

[0077] The two ends of the lap joint runner 322 are lap-jointed on the side walls of the upper and lower adjacent two straight runners 321, rather than directly aligned and connected; this means that after the metal liquid flows out of the previous straight runner 321, it must pass through a sharp turn of nearly 90 degrees to enter the lap joint runner 322, and then pass through a reverse sharp turn to flow into the next straight runner 321; the difference in inertial force generated by the fluid when changing the direction of motion can be used to separate impurities.

[0078] Different density of material (clean metal liquid vs. slag, bubbles, sand particles) has different mass, thus different inertia; when the metal liquid makes a sharp turn at the overlap runner 322; each overlap runner 322 is equivalent to an "inertia separator".

[0079] Multi-stage series, just form a multi-stage filter, the removal efficiency of impurities, especially light slag is extremely high.

[0080] Further, in the present application, the slow flow cross runner 41 end of the straight runner 3 away from the end of the pouring cup 1 is arc-shaped; at least one inner pouring unit 4 is connected to each straight flow runner 321; the slow flow cross runner 41 end is arc-shaped: ultimate streamline transition is realized; if the slow flow cross runner 41 is connected to the straight runner 3 at a right angle or an acute angle, a "flow dead zone" or a severe "vortex" will be formed at the corner; in the dead zone, the metal liquid is almost stationary, which will quickly solidify by heat dissipation, possibly blocking the flow channel or forming cold-separation inclusions; the streamline transition of the present application: the arc-shaped profile provides continuous and gradual streamline guidance for the metal liquid, enabling it to change the flow direction extremely smoothly; the turbulence, energy loss and air absorption caused by sudden change of flow direction are minimized, and the stable state of the metal liquid is maintained.

[0081] At the same time, the slow flow runner end is designed as an arc-shaped structure, which also plays a good avoiding role.

[0082] Further, in the present application, the pouring cup 1 comprises a stepped shape; the pouring cup 1 comprises an upper cup runner 11 and a lower cup runner 12; the upper cup runner 11 and the lower cup runner 12 are both inverted conical frustums; the minimum inner diameter of the upper cup runner 11 is not less than the maximum inner diameter of the lower cup runner 12; the pouring cup 1 of the present application is designed as a stepped shape: which means that a stepped shoulder is formed inside the pouring cup 1; when the metal liquid falls from the ladle, it first impacts on the bottom of the upper cup runner 11 (i.e. the stepped shoulder); the minimum inner diameter of the upper cup runner 11 (the bottom outlet) ≥ the maximum inner diameter of the lower cup runner 12 (the top inlet); when the metal liquid flow impacts on the shoulder of the step, its vertical downward kinetic energy is suddenly broken, which is converted into severe turbulence, realizing the first stage of forced deceleration; further, the impact speed and kinetic energy of the metal liquid are greatly weakened before entering the straight runner 3, which reduces the pressure of the entire system on high-speed flow processing from the source.

[0083] The physical barrier of the step: the stepped shoulder itself is a perfect slag dam. The slag floating to the surface of the upper cup runner 11 is mostly blocked by the "dam" in the upper cup and cannot enter the lower cup.

[0084] Inverted conical frustum shape: guide the metal liquid flow to the center, which helps to maintain the centripetal converging stream, reducing the impact and splashing on the cup wall.

[0085] A kind of pouring mold for brake caliper body support, including mold body, the mold body is equipped with support cavity 2 and the pouring system;Each support cavity 2 relative two sides are connected with the inner gate 43 in one pouring system respectively;In the present application, it requires symmetrical, multiple nodes to fill type smoothly;That is, each support cavity 2 relative two sides are connected with the inner gate 43 in one pouring system respectively;This means that a complete pouring system (including sprue cup 1, horizontal gate, straight gate 3, slow flow horizontal gate 41, riser 42 etc.) serves one casting cavity, and metal liquid is introduced from its two sides symmetric position;Through avoiding slag horizontal gate 2 distribution, finally form two or more metal liquid through complete purification and slow flow treatment, from left and right or front and back symmetric "key point" synchronous injection cavity.

[0086] For brake caliper body support, such as flat, long strip or having symmetrical structure casting, from single side pouring is extremely easy to cause far end metal liquid temperature too low, produce cold separation, filling deficiency or microstructure uneven. From opposite two sides simultaneously filling type, equivalent to shorten half of the filling distance of cavity, so that the whole cavity can be filled with temperature uniform metal liquid quickly and synchronously in very short time;This symmetrical filling mode, combined with the low speed, low temperature difference metal liquid provided by pouring system, can maximize the formation of parallel advancing laminar filling front, which is the ideal state to obtain high-quality castings.

[0087] Metal liquid enters from two sides evenly, and the temperature field and stress field generated during solidification are highly symmetrical, which can greatly reduce the distortion and residual stress of castings caused by uneven shrinkage, which is crucial for brake caliper body support requiring size accuracy and assembly accuracy.

[0088] The extremely pure and calm metal liquid treated by all links (sprue cup 1 dross, horizontal gate settlement, straight gate 3 inertia separation, riser 42 ultimate purification) is directly delivered to the most critical area of the cavity;This ensures high cleanliness of the cast body;Lower filling speed means that the scouring force on the cavity and sand core is minimal, which fundamentally prevents, reduces or avoids the occurrence of "sand eye" defects.

[0089] Multiple identical support cavities 2 can be arranged in the mold body;One pouring system is used with multiple support cavities 2, and the pouring system disclosed in the present application greatly improves the process stability (flow stability, low defect rate), so that the quality of castings produced by each mold is highly consistent, which is very suitable for mass production and high reliability production requirements of automobile parts.

[0090] The pouring system of the present application is a multi-layer, step-by-step flow control and purification system, and its core idea is to reduce the flow rate of metal liquid and remove impurities before filling the cavity.

[0091] Sprue unit (initial receiving and buffering); stepped inverted cone-shaped sprue cup 1 (upper cup gate 11 + lower cup gate 12); receiving the metal liquid injected by the ladle. The stepped and inverted cone design can preliminarily buffer the liquid flow, reduce splashing, and make part of the slag float and adhere to the cup wall.

[0092] Outer pouring unit (splitting and slag blocking); slag-avoiding cross gate 2 (large section in the middle + small section at the end) connecting two tapered straight gates 3. The straight gate 3 is internally a unique segmented staggered lap joint structure (tapered flat runner 31, straight runner 321, lap joint runner 322); slag-avoiding cross gate 2: the cross-sectional change (large in the middle and small at the end) can further reduce the flow rate, which is beneficial for the impurities to precipitate in the spacious middle cross gate 21.

[0093] Tapered cone shape of straight gate 3: ensures that the metal liquid does not suck air when falling under the action of gravity; segmented staggered lap joint is the key slag blocking design. When the metal liquid flows through each "lap joint runner 322", the flow direction changes, and impurities are more easily captured and retained at the corner or lap joint due to different densities and inertia, thereby achieving dynamic filtration.

[0094] Inner pouring unit 4 (ultimate flow buffering, feeding and smooth introduction): structure buffering cross gate 41 → circular tapered cone-shaped riser 42 (large end at the bottom, inlet / outlet position staggered) → inner gate 43 → casting cavity; buffering cross gate 41: located at the lower end of the riser 42, mainly introducing the metal liquid from the bottom into the riser 42.

[0095] Circular tapered cone riser 42 (core flow buffering chamber): the metal liquid enters the riser 42 from the bottom, which has a larger volume, and must first fill up, and then flow out from the higher side inner gate 43. This process converts kinetic energy (flow rate) into potential energy (liquid level rise), greatly reducing the flow rate and impact force of the liquid entering the cavity.

[0096] In the riser 42, the flow rate is suddenly reduced, providing time and space for bubble floating and light impurities floating.

[0097] Feeding: as a traditional riser 42 function, it provides liquid metal supply during casting solidification to prevent shrinkage holes and porosity.

[0098] The inlet and outlet (inner gate 43) are not on the same vertical line, forcing the liquid flow to change direction in the riser 42, further consuming energy and promoting impurity separation.

[0099] Obviously, the specific implementation of the present application is not limited by the above-mentioned manner, and various non-essential improvements using the method concept and technical solution of the present application are within the protection scope of the present application.

Claims

1. A slag-blocking and slow-flowing casting system, characterized in that, This includes the gating unit, the external gating unit, and the internal gating unit; The gating unit is connected to the inlet gating unit via the outer gating unit; The gating unit includes a gating cup; The external gating unit includes a sprue; the internal gating unit includes a riser and an internal gating system. The sprue is connected to the ingate via a riser; The inlet and outlet ends of the riser are staggered.

2. The slag-blocking and slow-flowing casting system according to claim 1, characterized in that, The external casting unit includes two straight casting channels; the pouring cup is connected to the two straight casting channels through a slag-avoiding horizontal pouring channel; each straight casting channel is provided with at least one set of internal casting units; the internal casting units on the two straight casting channels are distributed relatively to each other.

3. The slag-blocking and slow-flowing casting system according to claim 2, characterized in that, The slag-avoiding horizontal pouring channel includes a central horizontal pouring channel; both ends of the central horizontal pouring channel are connected to the straight pouring channel through an end horizontal pouring channel; the horizontal cross-sectional area of ​​the central horizontal pouring channel is larger than the horizontal cross-sectional area of ​​the end horizontal pouring channel.

4. The slag-blocking and slow-flowing casting system according to claim 2, characterized in that, The in-gating unit also includes a slow-flow horizontal gating system; the straight gating system is connected to the riser through the slow-flow horizontal gating system; The slow-flow horizontal gating system is located at the end of the riser away from the pouring cup.

5. A slag-covering and slow-flowing casting system according to claim 4, characterized in that, The riser is shaped like a frustum cone; the end of the riser with the larger horizontal cross section is located near the slow-flowing gating; the slow-flowing gating leads to the bottom of the riser, and the riser is connected to the casting cavity through the ingate.

6. The slag-blocking and slow-flowing casting system according to claim 2, characterized in that, The vertical cross-section of the sprue is truncated cone-shaped.

7. The slag-covering and slow-flowing casting system according to claim 2, characterized in that, The sprue includes a conical runner and a flow runner; the flow runner includes multiple straight runners and overlapping runners; adjacent straight runners are connected by overlapping runners; the two ends of the overlapping runner overlap onto a straight runner; the conical runner is connected to the adjacent straight runner.

8. The slag-blocking and slow-flowing casting system according to claim 7, characterized in that, The end of the slow-flowing horizontal runner away from the pouring cup of the direct runner is arc-shaped; each direct runner is connected to at least one inlet unit.

9. A slag-covering and slow-flowing casting system according to claim 1, characterized in that, The gating cup is stepped; the gating cup includes an upper gating runner and a lower gating runner; both the upper gating runner and the lower gating runner are inverted frustum cone shape; the minimum inner diameter of the upper gating runner is not less than the maximum inner diameter of the lower gating runner.

10. A casting mold for a brake caliper body bracket, characterized in that, The mold body includes a support cavity and a gating system as described in any one of claims 1-9; each support cavity is connected to an inner sprue in a gating system on opposite sides.

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