Combined pouring system and pouring mold with same

Abstract

The invention relates to the field of brake caliper pouring equipment, in particular to a combined type pouring system and a pouring mold with the same, and the combined type pouring system comprises a pouring gate unit, an outer pouring unit, a filtering unit and an inner pouring unit; the sprue unit comprises a sprue cup; the outer pouring unit comprises a straight pouring gate and a secondary transverse pouring gate; the sprue cup is connected with the secondary cross gate through the sprue; the filter unit comprises a filter screen arranged in the sprue; the inner casting unit comprises a riser and a riser neck; one or two riser necks are arranged on each riser; the secondary cross gate is connected with the riser neck through the riser; according to the combined pouring system disclosed by the invention, the number of the riser necks is set on the risers, so that the number of casting cavities connected with the risers is different; further, during actual design, the maximum number of casting cavities can be arranged according to the transverse space of the mold; the space of the mold body can be fully utilized, and meanwhile the casting efficiency can be improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of brake caliper pouring equipment, in particular to a combined 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 bodies) 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 riser necks connected in series. However, in practical applications, 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: Liquid flow impact and gas entrainment: When the metal liquid falls from the ladle into the sprue cup, the speed is high. If it directly enters the straight runner, it is easy to produce splashing, turbulence and entrain gas. The gas and primary oxidized slag enter the cavity with the liquid flow, resulting in defects such as porosity and slag eyes in the casting.

[0006] Limited slag blocking capability: The slag blocking effect of a single cross runner or only relying on the sprue cup is not good, and small impurities can easily penetrate into the cavity. If the filter screen is not properly positioned, it can be easily damaged by high-speed liquid flow or quickly clogged, affecting the filtering effect and pouring continuity.

[0007] Inadequate flow control: The cross section of traditional straight runners and cross runners changes simply, and the deceleration and flow stabilization of the metal liquid are limited. The liquid flow still has a large impact on the cavity, which is not conducive to sequential solidification and impurity floating.

[0008] Low mold space utilization: The pouring system layout is rigid, and to avoid the casting cavity or ensure strength, a large amount of mold transverse projection area is often occupied, limiting the number of castings that can be formed in a single pouring (module), affecting production efficiency and material utilization.

[0009] For symmetrical or multi-cavity layouts, the metal liquid flow, flow rate and temperature of cavities with different distances from the sprue may differ, resulting in different filling times and uneven quality of each casting.

[0010] The existing patent CN 204565061 U discloses a casting mold for producing a brake caliper body, and the casting mold can realize the pouring forming of the brake caliper body, but the patent has two straight sprues, which inevitably increases the horizontal size of the pouring system, and the number of arranged cavities is reduced for the same size mold.

[0011] Therefore, in order to improve or solve at least one of the above technical problems, it is necessary to improve the pouring system of the existing caliper body support. SUMMARY

[0012] The purpose of the present application is to provide a pouring system which can increase the number of casting cavity arrangements.

[0013] In order to achieve the above purpose, the technical scheme adopted by the present application is: A combined pouring system comprises a sprue unit, an outer pouring unit, a filtering unit and an inner pouring unit; The sprue unit is connected with the inner pouring unit through the outer pouring unit, and the filtering unit is connected to the outer pouring unit; The sprue unit comprises a sprue cup, the outer pouring unit comprises a straight sprue and a secondary cross sprue, the sprue cup is connected with the secondary cross sprue through the straight sprue, and the filtering unit comprises a filter screen arranged in the straight sprue; The inner pouring unit comprises a riser and a riser neck, and one or two riser necks are arranged on each riser; The secondary cross sprue is connected with the riser and the riser neck.

[0014] The outer pouring unit further comprises a primary cross sprue, and the sprue cup is connected with the straight sprue through the primary cross sprue.

[0015] A plurality of inner pouring units are arranged on the secondary cross sprue, the inner pouring units on the side of the secondary cross sprue close to the sprue cup are connected with the secondary cross sprue through upper inner pouring vertical sprues, and the inner pouring units on the side of the secondary cross sprue away from the sprue cup are connected with the secondary cross sprue through lower inner pouring vertical sprues.

[0016] The upper inner pouring vertical sprue comprises an upper connecting sprue, a middle connecting sprue and a lower connecting sprue, the upper connecting sprue is connected with the riser in the inner pouring unit, the upper connecting sprue is connected with the lower connecting sprue through the middle connecting sprue, the horizontal projection area of the upper connecting sprue and the lower connecting sprue is greater than that of the middle connecting sprue, the lower connecting sprue is connected to the secondary cross sprue, and the vertical section of the upper inner pouring vertical sprue is dumbbell-shaped or C-shaped.

[0017] The lower inner pouring vertical gate comprises an inner pouring nozzle gate and an inner pouring down gate; the lower inner pouring vertical gate is overlapped on the secondary cross gate; the length dimension of the horizontal projection of the inner pouring nozzle gate is greater than that of the inner pouring down gate; the width dimension of the horizontal projection of the inner pouring nozzle gate is smaller than that of the inner pouring down gate.

[0018] The straight gate comprises a tapered nozzle gate and a flow-through gate; the length dimension of the horizontal projection of the tapered nozzle gate is greater than that of the flow-through gate; the width dimension of the horizontal projection of the tapered nozzle gate is smaller than that of the flow-through gate; The flow-through gate comprises a straight gate connected to the tapered nozzle gate and a connecting gate; the straight gate is connected to the secondary cross gate through the connecting gate; the filter screen in the filter unit is arranged at the connecting position of the straight gate and the connecting gate.

[0019] The connecting gate is dumbbell-shaped in vertical section.

[0020] The secondary cross gate comprises two oppositely arranged single cross gates; the straight gate is connected to the two single cross gates respectively; the cross-sectional area dimension of the middle region of each single cross gate is smaller than that of the end region of the single cross gate.

[0021] The gate cup is ladder-shaped; the gate cup comprises an upper cup gate and a lower cup gate; the upper cup gate and the lower cup gate are both inverted frustum-shaped; the minimum inner diameter of the upper cup gate is not smaller than the maximum inner diameter of the lower cup gate.

[0022] A gating mold for a brake caliper body comprises a mold body, a casting cavity and a combined gating system arranged in the mold body; the inner pouring unit in the combined gating system is connected to one or two casting cavities.

[0023] The advantages of the present application are as follows: The present application discloses a combined gating system and a gating mold with the same.

[0024] The combined gating system disclosed by the present application can realize different numbers of casting cavities connected to each riser by setting different numbers of riser necks on the riser; further, the maximum number of casting cavities can be arranged in the mold in actual design; the space of the mold body can be fully utilized, and the casting efficiency can be improved.

[0025] In addition, the two-stage cross gate and the filter unit can realize good flow buffering and slag blocking effect, and can well reduce the kinetic energy of the metal liquid impacting the cavity wall, reduce the derived defects such as sand eye and air hole, reduce the cleaning workload of the casting by 30%, and improve the production efficiency by 20%.

[0026] Stepped inverted cone pouring cup: Simple structure achieves initial buffering and slag blocking.

[0027] The present invention employs a dumbbell-shaped or C-shaped structure for the upper inlet sprue, lower inlet sprue, and connecting sprue. This structure can slow down the flow and also effectively avoid obstacles, primarily to avoid the casting cavity. This allows the casting cavity and the gating system to partially overlap in the horizontal projection, thereby making better use of the lateral space of the mold body. Ultimately, this maximizes the number of casting cavities in the lateral direction and optimizes the number of products that can be produced by a single mold.

[0028] In addition, the upper inlet vertical gating channel, lower inlet vertical gating channel, connecting gating channel, conical flat gating channel and inlet flat gating channel of the present invention are all essentially variable cross-section gating channels: which can better control the flow rate of molten metal or remove impurities. Attached Figure Description

[0029] 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 casting system of the present invention.

[0030] Figure 2 This is a schematic diagram of the structure when the lower inlet vertical gating channel is connected to the riser in this invention.

[0031] The markings in the above figures are all: 1. Pour cup, 2. Sprue, 3. Primary runner, 4. Ingate unit, 5. Upper ingate sprue, 6. Lower ingate sprue, 7. Secondary runner, 8. Casting cavity, 9. Filter screen. Detailed Implementation

[0032] 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.

[0033] This invention provides a combined gating system. This gating system is particularly suitable for the production of castings such as brake caliper bodies. Through its unique structural design, it achieves smooth filling of molten metal, effective filtration of impurities, and efficient utilization of mold space.

[0034] The combined gating system mainly comprises four parts: a gating unit, an external gating unit, a filtration unit, and an internal gating unit 4. The gating unit is connected to the internal gating unit 4 via the external gating unit, providing a channel for the introduction and distribution of molten metal; the filtration unit is connected to the external gating unit and is used to purify the molten metal before it flows into the mold cavity; the internal gating unit 4 is responsible for smoothly introducing the clean molten metal into the casting mold cavity 8.

[0035] Specifically, the gating unit includes a stepped gating cup 1. This gating cup 1 comprises an upper frustum-shaped upper gating runner 11 and a lower frustum-shaped lower gating runner 12, with the minimum inner diameter of the upper gating runner 11 not less than the maximum inner diameter of the lower gating runner 12. This stepped frustum-shaped structure provides buffering and initial slag blocking during the initial pouring of molten metal, helping to reduce liquid splashing and air entrapment.

[0036] The external gating unit is used to guide and divert molten metal, and it includes a primary horizontal gating 3, a vertical gating, and a secondary horizontal gating 7.

[0037] The outlet of the lower gating runner 12 of the pouring cup 1 is first connected to the primary horizontal gating runner 3, which is then connected to the sprue runner 2, and finally the sprue runner 2 is connected to the secondary horizontal gating runner 7. This two-stage horizontal gating layout extends the flow path of the molten metal, which is beneficial for further stabilizing the liquid flow and removing slag.

[0038] The sprue 2 includes a conical runner 21 and a flow runner 22. The length of the horizontal projection of the conical runner 21 is greater than its width, while the length of the horizontal projection of the flow runner 22 is less than its width, resulting in a significant change in cross-sectional shape. In this invention, the conical runner 21 has a high coefficient of friction, which slows down the molten metal in the runner, reducing scouring and erosion, and limiting the flow of molten iron. This allows the primary horizontal runner 3 to fill quickly, and sand and slag impurities entering the primary horizontal runner 3 with the molten metal can float above the molten metal and be captured. Simultaneously, the conical runner 21 also allows the slowed molten iron to flow smoothly into the lower flow runner 22.

[0039] In this invention, the flow runner 22 further includes a direct runner 221 connected to the conical runner 21, and a connecting runner 222 connected to the secondary horizontal runner 7. The vertical cross-section of the connecting runner 222 is dumbbell-shaped. This variable cross-section design of the direct runner 2, especially the dumbbell-shaped structure of the connecting runner 222, can effectively regulate the flow rate of the molten metal and play a role in slowing down the flow at key connection points; at the same time, it also plays a good role in avoiding obstacles and facilitating the arrangement of the casting cavity 8.

[0040] In this invention, the secondary horizontal runner 7 includes two individual horizontal runners 71 symmetrically arranged along the sprue 2, and the connecting runner 222 of the sprue 2 is connected to these two individual horizontal runners 71 respectively. The design feature of each individual horizontal runner 71 is that the cross-sectional area of ​​its central region is smaller than the cross-sectional area of ​​its two end regions. This "large at both ends and small in the middle" structure causes the molten metal to slow down in the secondary horizontal runner 7.

[0041] The filtration unit includes a filter screen 9 disposed inside the direct sprue 2, preferably located at the connection between the direct sprue 221 and the connecting sprue 222. This is a critical point where the flow rate and direction of the molten metal change, and the filter screen 9 placed here can efficiently capture impurities flowing through, playing a core role in slag blocking and purification.

[0042] The ingate unit 4 is responsible for introducing the molten metal in the secondary runner 7 into the casting cavity 8. It includes a riser 41 and a riser neck 42 connecting the riser 41 and the casting cavity 8. Each riser 41 has one or two riser necks 42, which allows each riser 41 to be connected to one or two casting cavities 8, greatly enhancing the flexibility of the gating system layout.

[0043] Multiple inlet units 4 are connected to the secondary horizontal runner 7. In order to optimize the spatial layout and adapt to different filling requirements, the inlet unit 4 located on the side of the secondary horizontal runner 7 closer to the pouring cup 1 is connected to the secondary horizontal runner 7 through the upper inlet vertical runner 5; while the inlet unit 4 located on the side of the secondary horizontal runner 7 away from the pouring cup 1 is connected to the secondary horizontal runner 7 through the lower inlet vertical runner 6.

[0044] The upper ingate sprue 5 is composed of three sequentially connected parts: an upper gate 51, a middle gate 52, and a lower gate 53. The upper gate 51 is connected to the riser 41 of the ingate unit 4, and the lower gate 53 is connected to the secondary runner 7. The horizontal projected areas of both the upper gate 51 and the lower gate 53 are larger than that of the middle gate 52, resulting in a dumbbell-shaped or C-shaped vertical cross-section for the entire upper ingate sprue 5. This structure firstly provides excellent flow reduction and stabilization, and secondly, its special contour cleverly avoids adjacent casting cavities 8, allowing the gating system and the cavity to partially overlap in horizontal projection, thus saving lateral layout space in the mold.

[0045] The lower inlet sprue 6 includes an inlet flat gating sprue 61 and an inlet down gating sprue 62, which overlap the secondary horizontal gating sprue 7. The horizontal projection length of the inlet flat gating sprue 61 is greater than that of the inlet down gating sprue 62, but its width is smaller. This combination of a flat, elongated inlet and a wide outlet is a variable cross-section design, which helps control the flow of molten metal at this end position and also facilitates the breaking apart of adjacent risers 41.

[0046] The casting mold disclosed in this invention mainly includes a mold body, a casting cavity 8 for forming a brake caliper body and the aforementioned combined casting system.

[0047] Each ingate unit 4 in the combined gating system is connected to one or two casting cavities 8 via its riser neck 42. By adjusting the number of riser necks 42 and the layout of each part of the gating system, as many casting cavities 8 as possible can be arranged in the lateral space of the mold, making full use of the mold area and significantly improving the number of products and production efficiency per casting.

[0048] In practical implementation, it is generally required that an inlet unit 4 be set above and below a single horizontal gating system 71. In this invention, the upper inlet unit 4 is connected to the secondary horizontal gating system 7 through the upper inlet vertical gating system 5; the lower inlet unit 4 is connected to the secondary horizontal gating system 7 through the lower inlet vertical gating system 6. Based on this arrangement, the riser 41 in the upper inlet unit 4 serves as both a "slow flow chamber" and a "settling chamber": the molten metal enters from the bottom of the riser 41. Because the outlet (riser neck 4243) is laterally offset, the molten metal cannot flow out directly, but must first rise and turn inside the riser 41; this process converts a large amount of the kinetic energy of the high-speed liquid flow into potential energy (the liquid level rises), and the flow velocity decreases.

[0049] The lower inlet unit 4 is connected to the secondary horizontal runner 7 through the lower inlet vertical runner 6. Because the lower inlet vertical runner 6 adopts the inlet flat runner 61 and the inlet down runner 62, the lower inlet vertical runner 6 has a large coefficient of friction, which can reduce the speed of entering the lower inlet unit 4 and ensure the consistency of the punching of the upper and lower inlet units 4 as much as possible.

[0050] The present invention enables the gating system to be arranged closely by means of the flexible configuration of the number of riser necks 42 (one or two) and the special avoidance design (such as dumbbell shape or variable cross section) of the upper inlet sprue 5 and the lower inlet sprue 6, thus giving way to the casting cavity 8. This allows the maximum number of cavities to be arranged within the limited lateral space of the mold, greatly improving material utilization and single mold output.

[0051] A multi-stage buffering, deceleration, and filtration system is formed by the stepped pouring cup 1, the two-stage horizontal runner, the variable cross-section sprue 2 (especially the dumbbell-shaped connecting runner 222), and the filter screen 9 set at key nodes. This significantly reduces the impact kinetic energy of the molten metal on the mold cavity, effectively removes slag impurities, and reduces the risk of casting defects such as sand holes and porosity from the source.

[0052] Thanks to the aforementioned slow-flow and slag-blocking effects, the internal quality of the castings is guaranteed, and the subsequent cleaning workload can be reduced by approximately 30%. At the same time, the optimized layout increases the number of parts per mold, resulting in an overall production efficiency increase of approximately 20%.

[0053] The structure of the secondary horizontal runner 7, which is narrow in the middle and wide at both ends, helps to keep impurities away from the ingate and distribute the liquid flow evenly; the special shape of the lower ingate vertical runner 6 helps to fill and compensate for the shrinkage of the end cavity, further ensuring the uniformity of the casting quality.

[0054] A combined gating system includes a gating unit, an external gating unit, a filtering unit, and an internal gating unit 4. The gating unit is connected to the internal gating unit 4 via the external gating unit. The filtering unit is connected to the external gating unit. The gating unit includes a gating cup 1. The external gating unit includes a sprue 2 and a secondary runner 7. The gating cup 1 is connected to the secondary runner 7 via the sprue 2. The filtering unit includes a filter screen 9 arranged in the sprue 2. The internal gating unit 4 includes risers 41 and riser necks 42. Each riser 41 has one or two riser necks 42. The secondary runner 7 is connected to the riser necks 42 via the risers 41. The combined gating system disclosed in this invention uses a number of riser necks 42 on the risers 41. The quantity is not a problem, and the number of casting cavities 8 connected to each riser 41 can be different; thus, in actual design, the maximum number of casting cavities 8 can be arranged according to the horizontal space of the mold; it can make full use of the space of the mold body, and at the same time improve the casting efficiency; in this invention, the pouring cup 1 is connected to the conical flat runner 21 in the sprue 2 through the primary horizontal runner 3, and the lower end of the conical flat runner 21 is connected to the flow runner 22, and the middle area of ​​the flow runner 22 is provided with a filter screen 9; the lower end of the flow runner 22 is connected to the secondary horizontal runner 7, and the two ends of the secondary horizontal runner 7 are respectively provided with two in-gating units 4; the two in-gating units 4 on the left are each connected to two casting cavities 8, while the in-gating unit 4 on the right is connected to one casting cavity 8.

[0055] The external casting unit in this invention also includes a primary horizontal sprue 3, through which the pouring cup 1 is connected to the sprue 2. The primary horizontal sprue 3 mainly serves a connecting function, facilitating the connection between the pouring cup 1 and the sprue 2. It is the main channel connecting the pouring cup 1 and the sprue 2. The primary horizontal sprue 3 primarily serves a purification function; when molten metal flows into the pouring cup 1, the flow velocity is significantly reduced due to the increased cross-section. The primary horizontal sprue 3 provides initial buffering and flow stabilization space: its cavity provides initial expansion and deceleration space for the molten metal, helping to mitigate turbulence that may occur in the initial stage of pouring, making the flow more stable and creating conditions for further purification. The relatively gentle horizontal flow and certain channel length allow some denser primary inclusions to float to the top of the horizontal sprue in advance, achieving a "forward shift" of the slag-blocking function and reducing the burden on subsequent filtration units.

[0056] In this invention, multiple in-gating units 4 are provided on the secondary horizontal runner 7; the multiple in-gating units 4 are connected to the secondary horizontal runner 7, mainly for distributing molten metal to different casting cavities 8.

[0057] The ingate unit 4 on the side of the secondary horizontal runner 7 closest to the pouring cup 1 is connected to the secondary horizontal runner 7 via an upper ingate vertical runner 5; the ingate unit 4 on the side of the secondary horizontal runner 7 furthest from the pouring cup 1 is connected to the secondary horizontal runner 7 via a lower ingate vertical runner 6; based on the above design, it is possible to connect two relatively arranged ingate units 4 to the same secondary horizontal runner 7; in this invention, the upper ingate vertical runner 5 includes an upper connecting gate 51, a middle gate 52, and a lower connecting gate 53; the upper connecting gate 51 is connected to the riser 41 in the ingate unit 4; the upper connecting gate 51 is connected to the lower connecting gate 53 via the middle gate 52, and the horizontal projected area of ​​both the upper connecting gate 51 and the lower connecting gate 53 is larger than the horizontal projected area of ​​the middle gate 52; the lower connecting gate 53 is connected to the secondary horizontal runner 7, and the vertical cross-section of the upper ingate vertical runner 5 is matte. The inlet vertical runner 6 is bell-shaped or C-shaped; it includes an inlet flat runner 61 and an inlet down runner 62; the inlet vertical runner 6 overlaps with the secondary horizontal runner 7; the horizontal projection length of the inlet flat runner 61 is greater than the horizontal projection length of the inlet down runner 62; the horizontal projection width of the inlet flat runner 61 is less than the horizontal projection width of the inlet down runner 62; in this invention, the upper inlet vertical runner 5 and the lower inlet vertical runner 6 are essentially a connecting channel structure. In addition, in this invention, the connection method is specifically designed according to the different positions of the inlet units 4 on the secondary horizontal runner 7: the inlet units 4 located on the side of the secondary horizontal runner 7 closer to the pouring cup 1 are connected through the upper inlet vertical runner 5; while the inlet units 4 located on the end of the secondary horizontal runner 7 away from the pouring cup 1 are connected through the lower inlet vertical runner 6.

[0058] This differentiated connection design aims to optimize the filling state and shrinkage effect of different segments. The technical advantages of the upper inward pouring vertical runner 5 are: Throttling, stabilizing, and purifying: The narrowed cross-sectional area of ​​the central gate 52 creates local resistance, which can effectively reduce the flow rate of the molten metal, making the flow more stable. At the same time, it helps to cause residual impurities to float and remain in this area, playing a secondary purification role.

[0059] Space avoidance and layout optimization: Its unique dumbbell-shaped or C-shaped contour can cleverly avoid the protrusions or key parts of the casting cavity 8 below in vertical space, allowing the gating system and the casting cavity 8 to partially overlap in horizontal projection. This design greatly saves the lateral layout space of the mold, creating conditions for arranging more cavities within the mold.

[0060] The lower inlet sprue 6 adopts a different structure, which includes an inlet flat sprue 61 and an inlet down sprue 62, which are integrally connected to the end of the secondary horizontal sprue 7. Its structural features are: the length of the horizontal projection of the inlet flat sprue 61 is greater than that of the inlet down sprue 62, but its width is smaller than that of the inlet down sprue 62, that is, the inlet is narrow and long, and the outlet becomes relatively wide and short.

[0061] End flow control and smooth filling: The narrow and long inlet flat gating system 61 restricts the flow of molten metal, which can precisely control the flow rate and speed of molten metal filling the end cavity of the mold, and avoid turbulence or impact caused by excessive flow at the end.

[0062] Promote end-point feeding: The cross-section of the outlet (inner gating 62) is widened, which reduces the liquid flow velocity and increases the smoothness of the flow. This is conducive to the molten metal fully feeding the end casting cavity 8 under pressure, reducing the risk of shrinkage porosity and shrinkage defects in this area.

[0063] In summary, by designing different structures for the upper inlet sprue 5 and the lower inlet sprue 6, this invention achieves precise control of the molten metal flow in different sections of the gating system, while optimizing the mold space utilization rate and balancing casting quality and production efficiency.

[0064] In this invention, the sprue 2 includes a conical runner 21 and a flow runner 22. The length of the horizontal projection of the conical runner 21 is greater than the length of the horizontal projection of the flow runner 22. The width of the horizontal projection of the conical runner 21 is smaller than the width of the horizontal projection of the flow runner 22. The sprue 2 is a vertical channel connecting the primary runner 3 and the secondary runner 7, and its specific structure includes the upper conical runner 21 and the lower flow runner 22. The conical runner 21 has a long, flat shape with a length greater than its width in its horizontal projection, while the flow runner 22 has a wide, flat shape with a length less than its width in its horizontal projection, resulting in a significant cross-sectional transformation.

[0065] The flow channel 22 includes a direct flow channel 221 connected to the conical flow channel 21 and a connecting flow channel 222; the direct flow channel 221 is connected to the secondary horizontal flow channel 7 through the connecting flow channel 222; the filter screen 9 in the filter unit is arranged at the connection between the direct flow channel 221 and the connecting flow channel 222; the vertical cross section of the connecting flow channel 222 is dumbbell-shaped; by setting the filter screen 9 at the junction of the direct flow channel 221 and the connecting flow channel 222, the molten metal has completed the initial stabilization after falling from the conical flow channel 21, and the flow velocity is relatively uniform, which allows the filter screen 9 to withstand more balanced hydraulic impact, avoid local scouring damage, and at the same time ensure that the molten metal passes through the filter screen 9 in a better flow state, so as to achieve efficient interception and collection of impurities.

[0066] The dumbbell-shaped connecting runner 222 is characterized by a contracted middle section and expanded ends. When the molten metal passes through the filter screen 9 and enters the flat section, it increases the friction coefficient of the molten metal, thus playing a significant role in preventing slacking.

[0067] In other words, after the molten metal passes through the dumbbell-shaped connecting runner 222, it has a good flow stabilizing effect, which makes it easy for the molten metal to enter the secondary horizontal runner 7 in a smooth and uniform state.

[0068] This lays a solid foundation for the balanced distribution among multiple ingate units 4, effectively avoiding the problem of asynchronous filling of the various casting cavities 8 due to uneven liquid flow distribution.

[0069] The technical advantages of the above-mentioned direct gating system 2 structure of the present invention are as follows: Achieving a smooth transition in flow velocity and direction: The flat and elongated cross-section of the conical flow channel 21 can constrain and guide the molten metal flowing from the primary horizontal runner 3, causing it to smoothly transition to vertical downward flow; because of the flat design of the conical flow channel 21, the molten metal can have a large coefficient of friction in the initial stage, thereby reducing the impact force on the filter screen 9.

[0070] Optimize the flow pattern to facilitate the floating of impurities: The cross-sectional shape design can reduce the flow velocity of molten metal in the first-stage horizontal gating channel 3, making it easier for sand and slag impurities to float above the molten iron.

[0071] The variable cross-section design of the direct sprue 2 integrates multiple functions such as speed reduction, steering, flow stabilization, impurity pre-separation, and core filtration within a limited height space. Its compact structure saves space for the layout of other parts of the pouring system.

[0072] In this invention, the secondary horizontal runner 7 includes two opposing individual horizontal runners 71; the sprue 2 is connected to the two individual horizontal runners 71 respectively; the cross-sectional area of ​​the middle region of each individual horizontal runner 71 is smaller than the cross-sectional area of ​​the end of the individual horizontal runner 71; the narrowing of the middle region of the individual horizontal runner 71 in this invention can further reduce the speed of the molten metal in the secondary horizontal runner 7; when the molten metal flows from the sprue 2 into the narrower middle region of the secondary horizontal runner 7, the sudden contraction of the channel cross-section will produce a "throttling" effect on the liquid flow. This design is not for acceleration, but to consume the kinetic energy of the liquid flow by increasing local resistance. When the liquid flow subsequently enters the end expansion region, according to the principles of fluid mechanics, its flow velocity will decrease significantly, thereby achieving a further active reduction of the speed of the molten metal after the initial rectification by the sprue 2, allowing it to flow to each ingate unit 4 in a more gentle and stable state, further reducing the impact on the cavity.

[0073] Furthermore, 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, and 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 stepped shoulder itself is a perfect slag-blocking dam. Most of the slag that rises to the surface of the liquid in the upper cup gating channel 11 is blocked by this "dam" and cannot enter the lower cup; Inverted truncated cone shape: Guides the flow of molten metal towards the center, helps to maintain a concentric flow, and reduces the impact and splashing on the cup wall.

[0075] 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. A combined 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 includes a gating cup; the external gating unit includes a sprue and a secondary runner; the gating cup is connected to the secondary runner via the sprue; the filtering unit includes a filter screen arranged in the sprue. The ingate unit includes a riser and a riser neck; each riser has one or two riser necks. The secondary horizontal gating system is connected to the riser neck via a riser.

2. The combined casting system according to claim 1, characterized in that, The external gating unit also includes a primary horizontal gating system, and the gating cup is connected to the direct gating system through the primary horizontal gating system.

3. The combined casting system according to claim 1, characterized in that, Multiple inlet units are provided on the secondary runner; the inlet unit on the side of the secondary runner closest to the pouring cup is connected to the secondary runner via an upper inlet vertical runner; the inlet unit on the side of the secondary runner furthest from the pouring cup is connected to the secondary runner via a lower inlet vertical runner.

4. A combined casting system according to claim 3, characterized in that, The upper in-gating vertical runner includes an upper connecting gate, a middle gate, and a lower connecting gate; the upper connecting gate is connected to the riser in the in-gating unit; the upper connecting gate is connected to the lower connecting gate through the middle gate, and the horizontal projected area of ​​both the upper and lower connecting gates is larger than the horizontal projected area of ​​the middle gate; the lower connecting gate is connected to the secondary horizontal runner, and the vertical cross-section of the upper in-gating vertical runner is dumbbell-shaped or C-shaped.

5. A combined casting system according to claim 3, characterized in that, The lower inlet vertical runner includes an inlet flat-mouth runner and an inlet down runner; the lower inlet vertical runner overlaps on the secondary horizontal runner; the length of the horizontal projection of the inlet flat-mouth runner is greater than the length of the horizontal projection of the inlet down runner; the width of the horizontal projection of the inlet flat-mouth runner is smaller than the width of the horizontal projection of the inlet down runner.

6. A combined casting system according to claim 2, characterized in that, The sprue includes a conical runner and a flow runner; the length of the horizontal projection of the conical runner is greater than the length of the horizontal projection of the flow runner; the width of the horizontal projection of the conical runner is less than the width of the horizontal projection of the flow runner. The flow runner includes a direct runner and a connecting runner connected to the conical runner; the direct runner is connected to the secondary horizontal runner through the connecting runner; the filter screen in the filter unit is arranged at the connection between the direct runner and the connecting runner.

7. A combined casting system according to claim 6, characterized in that, The vertical cross-section of the connecting gating is dumbbell-shaped.

8. A combined casting system according to claim 1, characterized in that, The secondary horizontal gating system includes two opposing individual horizontal gating systems; the sprue is connected to the two individual horizontal gating systems respectively; the cross-sectional area of ​​the middle region of each individual horizontal gating system is smaller than the cross-sectional area of ​​the end region of the individual horizontal gating system.

9. A combined 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.

10. A casting mold for a brake caliper body, characterized in that, The system includes a mold body, which has a casting cavity and a combined gating system as described in any one of claims 1-9; the inlet unit in the combined gating system is connected to one or two casting cavities.

Images