Single-riser casting mold structure for casting differential shell of new energy automobile

Abstract

The utility model discloses a single-riser casting mold structure for casting a differential shell of a new energy automobile, each differential shell casting is only connected with one riser, and the riser is positioned at the top of a flange of the differential shell casting. According to the scheme, a single-riser process structure is adopted for feeding, under the condition that the number of the risers is reduced, the product quality can still be guaranteed, the requirements of customers for casting defects are met, the process yield is improved, additional materials do not need to be added for auxiliary feeding porosity, a machining procedure is omitted, the production cost is reduced, and the economic benefits are improved.

Description

Technical Field

[0001] This utility model belongs to the field of casting technology, specifically relating to a single riser casting mold structure for casting differential housings of new energy vehicles. Background Technology

[0002] In the casting industry, differential housings have stringent requirements regarding internal defects, and traditional production methods cannot fully meet customer needs. This is especially true for differential housings used in new energy vehicles, where customers demand zero internal defects (Level 1) during the early stages of product development, with particular emphasis on ensuring no defects exist in stress zones. As a crucial structural component of automobiles, the differential housing's safety is directly related to vehicle driving safety.

[0003] The differential housing is an outer shell that houses and protects the internal components of the differential, such as gears, and has a flange on the side with the larger opening. For example... Figure 4 As shown, the traditional production method usually involves setting risers on both sides of the flange (i.e., double risers 2', with a frustum structure that is smaller at the top and larger at the bottom) for feeding. This process has certain limitations and it is difficult to achieve ideal sequential solidification. For thicker flanges with concentrated heat, the double riser process is not ideal for feeding. Even if additional material is added to the casting for auxiliary feeding, the shrinkage porosity at the flange face and cylindrical root cannot be completely improved or removed to meet the customer's first-class standard. At the same time, the double riser process has a low yield, is difficult to clean, and the additional material added to the casting may even require an additional machining process to remove. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a single riser casting mold structure for the differential housing of new energy vehicles, which solves the problems of existing processes such as shrinkage porosity failing to meet the first-class standard, low process yield, and difficulty in cleaning, and achieves product quality while reducing the number of risers, and improves process yield.

[0005] According to the technical solution of this utility model, this utility model provides a single riser casting structure for differential housing of new energy vehicles, wherein each differential housing casting is connected to only one riser, and the riser is located on the top of the flange of the differential housing casting.

[0006] Furthermore, the riser is composed of two interconnected parts, the lower part of which is a cuboid structure and is connected to the differential housing casting. The upper part of the riser is a cylindrical structure, which is vertically oriented upwards, and the cross-section of the cylindrical structure of the upper part is smaller than the cross-section of the cuboid structure of the lower part.

[0007] Furthermore, the thickness of the lower cuboid structure is 3 to 4 times the thickness of the flange, the length is 100±10mm, and the height is 50±10mm.

[0008] Furthermore, a downward-recessed V-shaped groove is provided at the top of the upper cylindrical structure. The V-shaped tip of the groove is located at the axis of the cylindrical structure, and the opening of the groove faces the lateral side.

[0009] Furthermore, the included angle of the tip of the V-groove is 100°, and the vertical depth of the V-groove is 1 / 5 to 1 / 2 of the overall height of the riser.

[0010] Furthermore, the top of the upper cylindrical structure is hemispherical, and there is a smooth transition section between the upper and lower parts.

[0011] Furthermore, the upper half of the cuboid structure in the lower part has a larger dimension than the lower half.

[0012] Furthermore, it also includes a pouring cup, which is connected to the differential housing casting and riser via a gating system.

[0013] Furthermore, the pouring cup is located above the runner, the plane of the runner is vertical, and the plane of the flange of the differential housing casting is vertical.

[0014] Furthermore, there are two differential housing castings arranged side by side in the horizontal direction below the pouring cup.

[0015] Compared with the prior art, the beneficial technical effects of this utility model are as follows:

[0016] In the single-riser casting structure for the differential housing of new energy vehicles of this utility model, a single-riser process structure is adopted for feeding, that is, each casting is connected to only one riser, which is set on the top of the casting flange. More specifically, the riser shape is divided into two parts: the lower part is a roughly rectangular structure with a thickness of 3 to 4 times the flange thickness, a length of 100±10mm, and a height of 50±10mm; the upper part is a small cylindrical structure with a downward-facing V-groove at the center of the cylinder. The included angle of the tip of the V-groove is 100°, and the depth is 1 / 5 to 1 / 2 of the overall height of the riser. This riser structure can ensure sufficient pressure head and feed by its own weight, resulting in better feeding effect. Therefore, this solution can still ensure product quality and meet customer requirements for casting defects while reducing the number of risers, improve the process yield, and eliminate the need for additional materials for auxiliary feeding, reducing a processing step, lowering production costs, and improving economic efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the casting mold structure provided by this utility model.

[0018] Figure 2a yes Figure 1 A schematic diagram of the riser section in the middle.

[0019] Figure 2b yes Figure 2a A top view of the riser shown.

[0020] Figure 3a This is a schematic diagram of the riser portion of another embodiment of the present invention.

[0021] Figure 3b yes Figure 3a A top view of the riser shown.

[0022] Figure 4 This is a schematic diagram of an existing double riser mold structure.

[0023] Explanation of reference numerals in the attached figures:

[0024] 1. Differential housing casting; 2. Riser; 3. Lower part; 4. Upper part; 5. V-groove; 6. Sprue cup; 7. Sprue. Detailed Implementation

[0025] This utility model provides a single-riser casting mold structure for casting differential housings of new energy vehicles, which solves the problems of existing processes such as shrinkage porosity failing to meet first-class standards, low process yield, and difficulty in cleaning. It achieves product quality while reducing the number of risers and improving process yield.

[0026] Please see Figures 1 to 2b The present invention relates to a single-rise casting structure for a differential housing of a new energy vehicle, wherein each differential housing casting 1 is connected to only one riser 2, and the riser 2 is located on the top of the flange of the differential housing casting 1.

[0027] The basic structure of the differential housing casting 1 is based on existing technology, mainly comprising a cylindrical or bowl-shaped housing body. The axis of the housing body is generally through-holes at both ends. One end has a small through-hole located at the top of the housing body (as shown by the small circle in the center of the differential housing casting 1 in the figure), and the other end has a larger circular opening with a flange outside this opening (as shown by the ring on the outer side of the differential housing casting 1 in the figure). The flange, or lead flange, is used to bolt the differential housing to other components during assembly. Furthermore, in existing differential housing casting structures, the differential housing casting 1 is typically as follows... Figure 4 As shown in the vertical arrangement, the main improvement of this solution is that the risers originally located on both sides of the differential housing casting 1 are eliminated, and a riser is set only at the top (above) of the flange, so as to rely on gravity to compensate for the shrinkage at the root of the cylindrical surface of the flange and the housing body.

[0028] More specifically, please also refer to Figure 2a , Figure 2bThe riser 2 is composed of two integrally connected upper and lower parts. The lower part 3 of the riser 2 has a cuboid structure (more specifically, for example, a cuboid-like structure with rounded edges), and the lower part 3 is connected to the differential housing casting 1 (more specifically, for example, by overlapping / pressing with the flange). In the preferred embodiment, please refer to... Figure 3a , Figure 3b The thickness of the cuboid structure of the lower part 3 is 3 to 4 times the thickness of the flange (for example, a thickness of 70±10mm), the length is 100±10mm, and the height is 50±10mm. Optionally, the upper half of the cuboid structure of the lower part 3 is larger than the lower half, making the riser 2 relatively larger in volume and relatively higher in center of gravity, which helps to provide more feeding.

[0029] The upper part 4 of riser 2 has a cylindrical structure, which is vertically oriented upwards. The cross-section of the upper part 4 is smaller than the cross-section of the lower part 3's cuboid structure; in other words, the upper part 4 is a small cylindrical structure located at the center of the upper surface of the lower part 3 and extending upwards. In a preferred embodiment, a downward-recessed V-groove 5 is provided at the top of the cylindrical structure of the upper part 4. The V-shaped tip of the V-groove 5 is located at the axis of the cylindrical structure (appearing a V-shape from a top view), and the opening of the V-groove 5 faces laterally. The included angle of the tip of the V-groove 5 is, for example, 100°, and the vertical depth of the V-groove 5 is 1 / 5 to 1 / 2 of the overall height of riser 2. The cylindrical riser design is convenient and has a good feeding effect. The V-groove at the top of the feeding riser allows gas to escape more easily during casting, preventing it from being trapped inside the feeding riser, thereby reducing the probability of casting defects and improving the quality and process stability of ductile iron castings. This riser structure can ensure sufficient pressure head, allowing for feeding under its own weight, resulting in a feeding effect superior to the double riser process. And optionally, such as... Figure 2a As shown, the top of the cylindrical structure of the upper part 4 is hemispherical, and there is a smooth transition section between the upper part 4 and the lower part 3.

[0030] More specifically, the basic structure of the mold is based on existing technology, including, for example, a pouring cup 6, which is connected to the differential housing casting 1 and the riser 2 via a gating system 7; the gating system 7 includes, for example, horizontal, vertical, and arc-shaped gating channels, as well as water inlet plates connected to the differential housing casting 1 (fan-shaped portions on both sides below the differential housing casting 1 in the figure), thus forming the gating system. In this solution, as... Figure 1 As shown, the pouring cup 6 is located above the runner 7, the plane of which the runner 7 is located is vertical, and the plane of which the flange of the differential housing casting 1 is located is vertical. Optionally, there are two differential housing castings 1 arranged horizontally side by side below the pouring cup 6, so that two desired castings can be formed by a single pouring.

[0031] In summary, the single-riser casting structure for the differential housing of new energy vehicles of this utility model adopts a single-riser process for feeding, that is, each casting is connected to only one riser, which is set on the top of the casting flange. This riser structure can ensure sufficient pressure head and feed by its own weight, resulting in better feeding effect. Therefore, this solution can still ensure product quality and meet customer requirements for casting defects while reducing the number of risers, improve the process yield, and eliminate the need for additional materials for auxiliary feeding, reducing a processing step, lowering production costs, and improving economic efficiency.

Claims

1. A single-rise mold structure for casting differential housings in new energy vehicles, characterized in that, Each differential housing casting (1) is connected to only one riser (2), and the riser (2) is located on the top of the flange of the differential housing casting (1); The riser (2) is composed of two integrally connected upper and lower parts. The lower part (3) of the riser (2) is a cuboid structure and is connected to the differential housing casting (1). The upper part (4) of the riser (2) is a cylindrical structure and is vertically oriented upwards. The cross-section of the cylindrical structure of the upper part (4) is smaller than the cross-section of the cuboid structure of the lower part (3).

2. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to claim 1, characterized in that, The thickness of the cuboid structure of the lower part (3) is 3 to 4 times the thickness of the flange, the length is 100±10mm, and the height is 50±10mm.

3. The single-riseer casting mold structure for the differential housing of new energy vehicles according to claim 1, characterized in that, A downward-recessed V-shaped groove (5) is provided at the top of the cylindrical structure of the upper part (4). The V-shaped tip of the groove (5) is located at the axis of the cylindrical structure, and the opening of the groove (5) faces the lateral side.

4. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to claim 3, characterized in that, The included angle of the tip of the V-groove (5) is 100°, and the vertical depth of the V-groove (5) is 1 / 5 to 1 / 2 of the overall height of the riser (2).

5. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to any one of claims 1-4, characterized in that, The top of the cylindrical structure of the upper part (4) is hemispherical, and there is a smooth transition section between the upper part (4) and the lower part (3).

6. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to any one of claims 1-4, characterized in that, The upper half of the cuboid structure of the lower part (3) has a larger dimension than the lower half.

7. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to any one of claims 1-4, characterized in that, It also includes a pouring cup (6), which is connected to the differential housing casting (1) and the riser (2) via a gating system (7).

8. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to claim 7, characterized in that, The pouring cup (6) is located above the runner (7), the plane of the runner (7) is vertical, and the plane of the flange of the differential housing casting (1) is vertical.

9. The single-riseer casting mold structure for casting the differential housing of a new energy vehicle according to claim 7, characterized in that, Below the pouring cup (6) are two differential housing castings (1) arranged side by side in the horizontal direction.

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