Integrated pouring system and pouring mold with same

Abstract

The invention relates to the field of pouring systems, in particular to an integrated pouring system and a pouring mold with the same, and the integrated pouring system comprises a pouring gate unit, an outer pouring unit, a filtering unit and an inner pouring unit; the sprue unit is connected with the ingate unit through the ingate unit; the filtering unit is connected to the outer pouring unit; the sprue unit is connected with a plurality of ingate units through an ingate unit; the sprue unit comprises a sprue cup; the outer pouring unit comprises a sprue; the inner casting unit comprises a riser and a riser neck; the sprue is connected with the riser neck through the riser; the filter unit comprises a filter screen arranged in the sprue; according to the pouring system disclosed by the invention, one straight pouring gate is connected with a plurality of inner pouring units, so that the number of the straight pouring gates can be reduced, and meanwhile, the transverse occupied size of the pouring system is reduced.

Description

Technical Field

[0001] This invention relates to the field of gating systems, specifically to an integrated gating system and a gating mold having the gating system. Background Technology

[0002] In the production of metal castings, especially automotive safety components (such as brake calipers) that have stringent requirements for internal purity, mechanical properties and dimensional accuracy, the design of the gating system is crucial.

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

[0004] Traditional gating systems are typically composed of basic units such as pouring cups, sprues, runners, and riser necks connected in series. However, in practical applications, due to limitations in design concepts or structural details, it is often difficult to simultaneously and ideally achieve the two goals of "smooth filling" and "efficient slag removal," resulting in low casting yield and unstable quality.

[0005] The existing technology has the following main shortcomings: The system layout is not compact enough, resulting in low material utilization: To achieve simultaneous casting of multiple cavities, a common practice is to set up a separate branch system for each cavity or every two cavities, including a sprue, runner, and ingate. This approach results in the gating system occupying a large lateral space within the mold, increasing the overall mold size and consuming more molten metal in the gating system itself, leading to a lower material yield.

[0006] Unstable filtration effect and limited purification capacity: Although filtration technology has been widely used to remove inclusions from molten metal, traditional designs often place the filter screen in the runner or a single ingate. This dispersed arrangement may lead to inconsistent purity of the molten metal obtained from different cavities. Furthermore, the direct impact of high-speed molten metal flow on the filter screen can easily cause premature failure or clogging, affecting the durability and stability of the filtration effect.

[0007] The feeding and flow stabilization functions are not effectively coordinated: The main function of the riser is feeding, but its flow stabilization and buffering effects during the filling process are often overlooked. In traditional designs, molten metal often enters the riser directly or through a simple flow channel, failing to effectively utilize the riser cavity for sufficient kinetic energy dissipation and impurity flotation.

[0008] In addition, if the shape and liquid inlet method of the riser are not designed properly, it may be difficult to establish an ideal temperature gradient, affecting the feeding efficiency, or a larger riser volume may be required to ensure the feeding effect, increasing metal consumption.

[0009] Existing patent CN 204565061 U discloses a casting mold for producing brake caliper bodies. The casting mold disclosed in this patent can realize the casting and molding of brake caliper bodies. However, this patent has two sprues, which will inevitably increase the lateral dimension of the gating system. For the same size mold, the number of cavities will be reduced.

[0010] Therefore, in order to improve or solve at least one of the above-mentioned technical problems, it is necessary to improve the existing gating system of the clamp support. Summary of the Invention

[0011] The purpose of this invention is to provide a gating system that can reduce the lateral space occupied by the gating system.

[0012] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An integrated gating system includes a gating unit, an external gating unit, a filtration unit, and an internal gating unit; The gating unit is connected to the inlet gating unit via the outer gating unit; the filter unit is connected to the outer gating unit. The gating unit is connected to multiple inlet gating units via an 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 a riser neck. The sprue is connected to the riser neck via a riser; the filtration unit includes a filter screen installed inside the sprue.

[0013] The sprue includes an upper connecting runner and a flow runner; the flow runner includes multiple direct runners and overlapping runners; adjacent direct runners are connected through overlapping runners; the two ends of the overlapping runner overlap onto a direct runner; the upper connecting runner is connected to the adjacent direct runner.

[0014] The upper gating system includes an upper gating system and a filter gating system; the upper gating system is connected to the pouring cup, and the upper gating system is connected to the flow gating system through the filter gating system; the maximum area of ​​the water surface cross-section of the upper gating system is smaller than the maximum area of ​​the horizontal cross-section of the filter gating system; the filter screen is arranged inside the filter gating system.

[0015] The ingate unit is connected to the sprue via a cross runner; the sprue is connected to the riser via a cross runner; the cross runner is connected to the end of the riser away from the pouring cup.

[0016] The cross-flow gating system includes a horizontal flat gating system and a bridging gating system; the straight gating system is connected to the bridging gating system via the horizontal flat gating system; one end of the bridging gating system is connected to the end of the horizontal flat gating system away from the straight gating system, and the other end is connected to the riser.

[0017] The bridging gating channel is an arc-shaped gating channel.

[0018] The riser is shaped like a frustum cone; the end of the riser with the larger horizontal cross section is located close to the cross runner; the cross runner leads to the bottom of the riser, and the riser is connected to the casting cavity through the riser neck.

[0019] 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 cones; the minimum inner diameter of the upper gating runner is not less than the maximum inner diameter of the lower gating runner.

[0020] The in-sinking units on the direct casting run are arranged in a relatively symmetrical manner.

[0021] A casting mold for a brake caliper body includes a mold body, wherein a casting cavity and a gating system are provided within the mold body; each in-gating unit is connected to a casting cavity.

[0022] The advantages of this invention are: This invention discloses an integrated casting system and a casting mold having the casting system.

[0023] The gating system disclosed in this invention uses a sprue to connect multiple in-gating units, which can reduce the number of sprues and reduce the lateral size occupied by the gating system.

[0024] In addition, the gating system of the present invention is connected through the middle of the riser, which can play a good role in feeding and shrinking, and at the same time, the riser acts as a flow slower, reducing the flow rate of liquid entering the casting cavity; when the riser is in use, liquid enters from the lower end and exits from the side, so that the riser acts as a flow slower.

[0025] In addition, the present invention adopts a frustum-shaped riser design, which can reduce the amount of molten metal stored, thereby reducing the cost of using molten metal to a certain extent.

[0026] This invention, through the combined use of stepped pouring cups, filtering units, and cross-flow runners, can form multi-stage impurity removal, and can also effectively reduce the kinetic energy of molten metal impacting the mold cavity wall, reduce derivative defects such as sand holes and porosity, reduce the amount of casting cleaning work, and improve production efficiency. Attached Figure Description

[0027] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings: Figure 1 This is a schematic diagram of the structure of the present invention.

[0028] The markings in the above figures are all: 1. Pour cup, 2. Sprue, 3. Casting cavity, 4. Filter screen, 5. Ingate unit, 6. Cross runner. Detailed Implementation

[0029] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and the description of the preferred embodiments.

[0030] This invention provides an integrated casting system and a casting mold for a brake caliper body using the same system.

[0031] The core design of this casting system is to connect multiple in-cast units 5 in series through a common sprue 2 to form a compact layout, and to integrate multi-stage flow stabilization, filtration and shrinkage compensation functions.

[0032] Specifically: The gating system disclosed in this invention mainly includes a gating unit, an external gating unit, a filtering unit, and an internal gating unit 5.

[0033] The gating unit is used to receive and initially guide the molten metal from the ladle. Specifically, it includes a stepped gating cup 1, which consists of an upper cup gating 11 in the shape of an inverted frustum and a lower cup gating 12 in the shape of an inverted frustum.

[0034] The minimum inner diameter of the lower end of the upper gating 11 is not less than the maximum inner diameter of the upper end of the lower gating 12, thus forming a stepped transition. This stepped structure can effectively receive the molten metal, slow down its initial falling speed, achieve preliminary flow stabilization and slag removal, and reduce air and initial impurities entrained in the liquid flow.

[0035] The main body of the external gating unit is the sprue 2, which is responsible for conveying the molten metal from the gating unit downwards and distributing it to each internal gating unit 5.

[0036] The sprue 2 is further subdivided into an upper gating 21 and a flow gating 22 located below it. The upper gating 21 includes an upper gating 211 directly connected to the lower gating 12 of the pouring cup 1, and a filter gating 212 connecting the upper gating 211 and the flow gating 22. The maximum horizontal cross-sectional area of ​​the filter gating 212 is designed to be larger than the maximum water surface cross-sectional area of ​​the upper gating 211, forming an enlarged cross-sectional area. This design creates gentle flow conditions for subsequent filtration.

[0037] The filtration unit is integrated into the external gating unit, specifically consisting of one or more filter screens 4 disposed within the filter gating channel 212. Because the molten metal first flows through the smaller cross-section upper gating channel 211 and then enters the larger cross-section filter gating channel 212, the flow velocity is reduced, allowing it to pass through the filter screen 4 in a more stable flow pattern. This not only efficiently removes inclusions from the molten metal but also significantly reduces the direct impact of the high-speed molten metal on the filter screen 4, effectively extending the service life of the filter screen 4 and improving the stability of the filtration effect.

[0038] The flow gating system 22 is used to distribute the filtered molten metal to multiple branch gating units 5. It includes multiple vertically extending direct-flow gating systems 221 and overlapping gating systems 222 connecting adjacent direct-flow gating systems 221. Each overlapping gating system 222 overlaps with two direct-flow gating systems 221 at both ends, allowing the multiple direct-flow gating systems 221 to be interconnected vertically, forming a continuous distribution network. The uppermost direct-flow gating system 221 is connected to the filter gating system 212.

[0039] In this invention, multiple ingate units 5 are provided, which are connected to the sprue 2 (specifically, the flow sprue 22) via a cross-flow sprue 6. In this embodiment, these ingate units 5 are relatively symmetrically distributed with the sprue 2 as the center. Each ingate unit 5 includes a riser 51 and a riser neck 52 connecting the riser 51 to the casting cavity 3.

[0040] The cross-flow grate 6 is a crucial channel connecting the sprue 2 and the riser 51, designed to further regulate the flow direction and velocity of the molten metal. It includes a horizontal flat grate 61 directly connected to the sidewall of the straight grate 221, and a bridging grate 62 connected to the end of the horizontal flat grate 61. The cross-section of the horizontal flat grate 61 typically narrows along the flow direction, acting as a throttling and velocity-reducing agent, while the subsequent bridging grate 62 is designed in an arc shape. The arc-shaped bridging grate 62 can gently change the flow direction of the molten metal, gradually shifting the predominantly downward flow from the sprue 2 to an upward flow towards the riser 51. This process consumes the molten metal's kinetic energy through wall friction and flow direction changes, achieving stable flow.

[0041] In this invention, the riser 51 is designed as a frustum-shaped cone, with its larger horizontal cross-section end (i.e., the bottom) facing and connecting to the cross runner 6, while its smaller top section connects to the casting cavity 3 via the riser neck 52. When the molten metal flows in from the cross runner 6, it first enters the bottom of the riser 51. This unique "bottom-entry, side-exit" design makes the riser 51 cavity a highly efficient slow-flow and feeding chamber. The flow velocity of the molten metal decreases sharply within the riser 51, which is beneficial for the flotation and separation of gases and light impurities, achieving further purification of the molten metal. At the same time, the high-temperature molten metal stored in the riser 51 can be effectively fed through the riser neck 52 during the casting solidification process, preventing shrinkage cavities and porosity defects.

[0042] While ensuring the feeding effect, the truncated cone shape reduces the amount of molten metal stored compared to cylindrical designs, thus saving production costs.

[0043] A casting mold for a brake caliper body includes a mold body with a shared integrated gating system and multiple independent casting cavities 3 within it. Each ingate unit 5 of the gating system (i.e., each riser 51 and riser neck 52) is individually connected and corresponds to a casting cavity 3. During operation, the molten metal flows sequentially through a stepped gating cup 1, a sprue 2 with a filter screen 4, a distribution network-type flow runner 22, and a cross-flow runner 6 with a flow stabilizing function, finally entering the frustum-shaped riser 51, which has both flow-slowing and shrinkage-compensating functions, and then smoothly filling the casting cavity 3 of the brake caliper body.

[0044] The advantages of the above design are as follows: Overall integrated layout: A single sprue 2 connects multiple ingate units 5, which significantly reduces the lateral space occupied by the gating system within the mold, making the mold structure more compact and particularly suitable for high-efficiency production scenarios with multiple parts per mold.

[0045] Multi-stage impurity removal and flow stabilization: Through the multi-stage design of “stepped pouring cup 1 (preliminary flow stabilization and slag removal) → enlarged cross-section filtration zone (high-efficiency filtration) → arc-shaped turning flow channel (secondary flow stabilization) → riser 51 slow flow chamber (final purification)”, the flow rate of molten metal is reduced layer by layer and impurities are removed, which significantly reduces the impact of high-speed liquid flow on the mold cavity and effectively reduces defects such as sand holes and porosity in castings.

[0046] Optimized feeding design: Riser 51 adopts a bottom inlet and side outlet method. Combined with its frustoconical shape, it not only gives full play to the feeding function, but also realizes the slow flow of molten metal and the floating of impurities. At the same time, it reduces the metal consumption of the process riser 51 itself and saves costs.

[0047] In summary, the gating system disclosed in this invention reduces the workload of casting cleaning, improves the casting yield and production efficiency, and is especially suitable for the production of castings with high quality requirements, such as brake caliper bodies.

[0048] An integrated gating system according to the present invention includes a gating unit, an external gating unit, a filtering unit, and an internal gating unit 5; the gating unit is connected to the internal gating unit 5 through the external gating unit; the filtering unit is connected to the external gating unit; the gating unit is connected to multiple internal gating units 5 through the external gating unit; the gating unit includes a gating cup 1; the external gating unit includes a sprue 2; the internal gating unit 5 includes a riser 51 and a riser neck 52; the sprue 2 is connected to the riser neck 52 through the riser 51; the filtering unit includes a filter screen 4 disposed in the sprue 2; the internal gating units 5 disposed on the sprue 2 are relatively symmetrically distributed; the gating system disclosed in the present invention uses one sprue 2 to connect multiple internal gating units 5, which can reduce the number of sprues 2 and reduce the lateral size occupied by the gating system.

[0049] The gating unit disclosed in this invention serves as the inlet of the gating system, receiving molten metal poured from the ladle. Its structure (such as a stepped or funnel shape) can initially stabilize the liquid flow, separate some slag, and prevent air entrapment, providing a smoother initial flow of molten metal for subsequent processes.

[0050] The external gating unit, serving as the main conveying channel and distribution hub of the system, guides and distributes the molten metal from the gating cup 1 to multiple downstream branches; it is generally a vertically arranged main channel (straight gate 2); subsequently, the filling pressure is established by the weight of the molten metal. By designing a branch structure, it can simultaneously and evenly distribute the molten metal from one inlet to multiple internal gating units 5, which is the core of realizing "integrated" multi-cavity gating, significantly saving mold space and molten metal consumption.

[0051] The filtration unit acts as a purification checkpoint in the gating system, physically intercepting non-metallic inclusions (such as slag and oxides) in the molten metal. The filter screen 4 (usually made of ceramic or fiber) is integrated into the sprue 2 to force-filter all the molten metal flowing downstream. This can significantly improve the purity of the casting material, effectively reduce casting defects (such as slag inclusions and porosity) caused by inclusions, and improve the internal quality and performance consistency of the casting.

[0052] The ingate unit 5 serves as the final interface between the system and the casting cavity 3, as well as a buffer and feeding chamber, controlling the final state of the molten metal entering the cavity.

[0053] The key function of riser 51 is to compensate for shrinkage. During the solidification process of the casting, the high-temperature molten metal stored in riser 51 can compensate for the volume shrinkage of the casting through riser neck 52, preventing shrinkage cavities and porosity. At the same time, it also acts as a buffer pool, which can further stabilize and homogenize the liquid flow from sprue 2.

[0054] Riser neck 52 is used to connect riser 51 to casting cavity 3.

[0055] In this invention, the sprue 2 includes an upper connecting sprue 21 and a flow sprue 22; the flow sprue 22 includes multiple straight sprues 221 and overlapping sprues 222; adjacent straight sprues 221 are connected through overlapping sprues 222; the two ends of the overlapping sprues 222 are respectively overlapped on a straight sprue 221; the upper connecting sprue 21 is connected to the adjacent straight sprues 221; the upper connecting sprue 21 is mainly used to facilitate the connection between the sprue 2 and the pouring cup 1; the flow sprue 22 includes multiple vertical straight sprues 221 and overlapping sprues 222; the straight sprues 221 and overlapping sprues 222 are alternately connected, so that the flow sprue 22 forms a labyrinth structure, which is beneficial for separating impurities.

[0056] The two ends of the overlapping gating 222 overlap with the side walls of two adjacent straight gating 221, rather than being directly aligned and connected. This means that after the molten metal flows out of the previous straight gating 221, it must make a sharp turn of nearly 90 degrees before entering the overlapping gating 222, and then make a sharp turn in the opposite direction before flowing into the next straight gating 221. This can utilize the difference in inertial force generated when the fluid changes direction of movement to separate impurities.

[0057] Substances of different densities (clean molten metal vs. slag, bubbles, and sand particles) have different masses and therefore different inertia. When the molten metal makes a sharp turn at the overlapping gating channel 222, each overlapping gating channel 222 is equivalent to an "inertia separator". The multi-stage series connection forms a multi-stage filtration system, which has a very high efficiency in removing impurities, especially light slag.

[0058] In this invention, the upper gating system 21 includes an upper gating system 211 and a filter gating system 212. The upper gating system 211 is connected to the pouring cup 1, and the upper gating system 211 is connected to the flow gating system 22 via the filter gating system 212. The maximum area of ​​the water surface cross-section of the upper gating system 211 is smaller than the maximum area of ​​the horizontal cross-section of the filter gating system 212. The filter screen 4 is arranged inside the filter gating system 212. The upper gating system 21 is clearly divided into two sections: the upper gating system 211 (connecting to the pouring cup 1) and the filter gating system 212 (connecting to the downstream flow gating system 22). This essentially modularizes and makes the filtration area independent.

[0059] This invention requires that the maximum area of ​​the water surface cross-section of the upper gating 211 be smaller than the maximum area of ​​the horizontal cross-section of the filter gating 212. This creates a flow channel structure with a sudden expansion of the cross-section. When the molten metal first flows through the upper gating 211 with a smaller cross-section and enters the filter gating 212 with a significantly larger cross-section, its flow velocity will naturally decrease. This avoids the direct and violent impact of the high-speed liquid flow on the filter screen 4.

[0060] The reduction in flow rate significantly reduces the dynamic pressure impact and shear force of the molten metal on the filter screen 4, effectively preventing the filter screen 4 from being prematurely destroyed, broken, or blocked, and significantly improving the reliability and service life of the filter screen 4.

[0061] The lower, more stable flow rate allows impurities in the molten metal more time to come into contact with and be effectively intercepted by the filter screen 4. At the same time, the stable laminar flow trend helps to reduce turbulence and prevents intercepted impurities from being re-entered by the liquid flow, thereby improving the purity and stability of the filtration.

[0062] In this invention, the ingate unit 5 is connected to the sprue 2 via a cross-flow gating 6; the sprue 2 is connected to the riser 51 via the cross-flow gating 6; the cross-flow gating 6 is connected to the end of the riser 51 furthest from the pouring cup 1; the cross-flow gating 6 provides excellent lateral connection and connectivity, facilitating the connection between the riser 51 and the sprue 2, and connecting the cross-flow gating 6 to the end of the riser 51 furthest from the pouring cup 1; ensuring that the hotter molten metal first enters the riser 51 from the bottom; achieving a purification process of "bottom injection, slow flow upward": after the molten metal enters from the bottom of the riser 51 through the cross-flow gating 6, the flow direction changes from horizontal (or oblique) to upward. During this process: the velocity naturally decreases: the change in flow direction and cross-sectional area consumes kinetic energy; this is beneficial for impurities to float: in the relatively calm riser 51 cavity, the rising velocity of the molten metal slows down, providing time and space for the gas and light inclusions carried therein to float and separate, thus achieving purification within the gating system.

[0063] Through the transition of the cross runner 6, the molten metal from the sprue 2, which may still have a certain velocity and turbulence, undergoes sufficient "energy dissipation" and "flow stabilization" within the riser 51 before entering the casting cavity 3. This makes the molten metal that finally enters the cavity through the riser neck 52 flow at a stable velocity and with a controllable direction, greatly reducing the direct impact on the cavity (especially weak parts), thereby reducing the risk of defects such as sand holes, sand erosion, and air entrapment.

[0064] In this invention, the cross-flow gating 6 includes a transverse flat gating 61 and a bridging gating 62; the straight gating 2 is connected to the bridging gating 62 via the transverse flat gating 61; one end of the bridging gating 62 is connected to the end of the transverse flat gating 61 away from the straight gating 2, and the other end is connected to the riser 51; the bridging gating 62 is an arc-shaped gating; the transverse flat gating 61 is directly connected to the side wall of the straight gating 2, the transverse flat gating 61 is arranged transversely, the vertical cross section of the transverse flat gating 61 is rectangular, the transverse flat gating 61 increases the contact with the edge area of ​​the molten metal, increasing the friction coefficient of the molten metal flow, which can play a good role in slowing down the flow; the bridging gating 62 connects the end of the transverse flat gating 61 and the inlet of the riser 51, serving as the final connecting bridge.

[0065] The design of the horizontal flat gating 61 with its shrinking cross section is equivalent to increasing the flow obstruction section. Because it has a large coefficient of friction, it can slow down the molten metal in the horizontal flat gating 61. By precisely designing the cross section ratio of the horizontal flat gating 61, the initial flow rate and velocity of the molten metal distributed to each ingate unit 5 can be quantitatively controlled, so as to achieve balanced filling of multiple ingate units 5.

[0066] The core function of the bridging runner 62 is to gently change the flow direction of the molten metal. The bridging runner 62 smoothly redirects and guides the high-speed molten metal flow, which is ejected from the transverse flat runner 61 and mainly points outward, towards the inlet direction of the riser 51. In this process, a large amount of the impact kinetic energy of the molten metal is consumed through the friction between the fluid and the runner wall, as well as the change in flow direction itself.

[0067] After being guided and buffered by the bridging runner 62, the molten metal enters the riser 51 from a preset position (usually the bottom center or lower side of the riser 51) with a more stable flow and a more suitable speed, avoiding direct impact of the liquid flow on the riser 51 wall or cavity.

[0068] The combination of the transverse flat runner 61 and the bridging runner 62 realizes a flow management strategy of constrained deceleration and rear-direction buffering; it can better solve the impact and turbulence problems caused by high-speed liquid flow and ensure the stability of filling.

[0069] In this invention, the riser 51 is shaped like a frustum of a cone; the larger end of the horizontal cross-section of the riser 51 is located near the cross runner 6; the cross runner 6 leads to the bottom of the riser 51, and the riser 51 is connected to the casting cavity 3 through the riser neck 52; the riser 51 is smaller at the top and larger at the bottom, like an inverted funnel; the cross runner 6 is connected to the bottom of the larger end, and the riser neck 52 is connected to the side of the riser 51: the molten metal enters from the center of the wide bottom, must fill the internal volume of the riser 51 upwards, and then flow out from the side of the riser 51; this achieves ultimate slow flow and kinetic energy dissipation; when the molten metal enters the spacious bottom of the riser 51 from the bottom cross runner, a "sudden expansion" occurs, and the flow rate decreases. Subsequently, the liquid flow needs to move upwards to raise the liquid level within the entire riser 51, a process that converts most of the remaining kinetic energy into potential energy (liquid level height).

[0070] When the molten metal flows out from the side of riser 51, the flow rate of the molten metal is relatively reduced, which helps to eliminate defects such as air entrapment and sand flushing caused by high-speed filling.

[0071] With its truncated cone shape and bottom inlet, riser 51 becomes a highly efficient "flotation-sedimentation combined separator," completing the final purification of the molten metal.

[0072] High-temperature molten metal is injected from the bottom of riser 51, naturally forming an ideal temperature gradient where the bottom is hot and the top is relatively cool. This ensures that riser 51 is the last to solidify during the casting solidification process, keeping the feeding channel unobstructed and providing high feeding pressure; significantly improving the feeding capacity of the casting, effectively preventing shrinkage cavities and porosity defects, and increasing the density of the casting.

[0073] In this invention, the pouring cup 1 is stepped; the pouring cup 1 includes an upper gating channel 11 and a lower gating channel 12; both the upper gating channel 11 and the lower gating channel 12 are inverted frustum cones; the minimum inner diameter of the upper gating channel 11 is not less than the maximum inner diameter of the lower gating channel 12; the stepped design of the pouring cup 1 in this invention means that a stepped platform is formed inside the pouring cup 1. When the molten metal falls from the ladle, it first impacts the bottom of the upper gating channel 11 (i.e., the shoulder of the stepped platform); the minimum inner diameter of the upper gating channel 11 (bottom outlet) is greater than or equal to the maximum inner diameter of the lower gating channel 12 (top inlet); when the molten metal flows and hits the shoulder of the stepped platform, its vertical downward kinetic energy is suddenly interrupted and transformed into violent turbulence, achieving the first stage of forced deceleration; thus, before the molten metal enters the sprue 2, its impact speed and kinetic energy have been greatly weakened, reducing the pressure of the entire system on high-speed flow processing from the source.

[0074] Physical barrier of the steps: The step shoulder itself is a perfect slag-blocking dam. Most of the molten slag that rises to the surface of the upper cup gating channel 11 is blocked by this "dam" in the upper cup and cannot enter the lower cup.

[0075] Inverted truncated cone shape: guides the molten metal flow towards the center, helps maintain a concentric flow, and reduces impact and splashing on the cup wall.

[0076] Obviously, the specific implementation of this invention is not limited to the above-described methods. Any non-substantial improvements made using the inventive concept and technical solution of this invention are within the protection scope of this invention.

Claims

1. An integrated casting system, characterized in that, It includes a gating unit, an external gating unit, a filter unit, and an internal gating unit; The gating unit is connected to the inlet gating unit via the outer gating unit; the filter unit is connected to the outer gating unit. The gating unit is connected to multiple inlet gating units via an 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 a riser neck. The sprue is connected to the riser neck via a riser; the filtration unit includes a filter screen installed inside the sprue.

2. The integrated casting system according to claim 1, characterized in that, The sprue includes an upper connecting runner and a flow runner; the flow runner includes multiple direct runners and overlapping runners; adjacent direct runners are connected through overlapping runners; the two ends of the overlapping runner overlap onto a direct runner; the upper connecting runner is connected to the adjacent direct runner.

3. The integrated casting system according to claim 2, characterized in that, The upper gating system includes an upper gating system and a filter gating system; the upper gating system is connected to the pouring cup, and the upper gating system is connected to the flow gating system through the filter gating system; the maximum area of ​​the water surface cross-section of the upper gating system is smaller than the maximum area of ​​the horizontal cross-section of the filter gating system; the filter screen is arranged inside the filter gating system.

4. The slag-blocking and slow-flowing casting system according to claim 1, characterized in that, The ingate unit is connected to the sprue via a cross runner; the sprue is connected to the riser via a cross runner; the cross runner is connected to 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 cross-flow gating system includes a horizontal flat gating system and a bridging gating system; the straight gating system is connected to the bridging gating system via the horizontal flat gating system; one end of the bridging gating system is connected to the end of the horizontal flat gating system away from the straight gating system, and the other end is connected to the riser.

6. The slag-blocking and slow-flowing casting system according to claim 5, characterized in that, The bridging gating channel is an arc-shaped gating channel.

7. A slag-blocking 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 close to the cross runner; the cross runner leads to the bottom of the riser, and the riser is connected to the casting cavity through the riser neck.

8. An integrated 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 cones; the minimum inner diameter of the upper gating runner is not less than the maximum inner diameter of the lower gating runner.

9. An integrated casting system according to claim 1, characterized in that, The in-sinking units on the direct casting run are arranged in a relatively symmetrical manner.

10. A casting mold for a brake caliper body, characterized in that, The mold body includes a casting cavity and a gating system as described in any one of claims 1-9; each ingate unit is connected to a casting cavity.

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