Inclined type engineering van brake disc pouring mold device

Abstract

The utility model relates to the technical field of mold manufacturing, in particular to an inclined type engineering truck brake disc pouring mold device which comprises a sand box, a brake disc model and a pouring gate system, and is different from the prior art that the far end, far away from the pouring gate system, of the brake disc model is inclined downwards. Compared with the prior art, through the inclined structural design, the molten iron mold filling and feeding effects are fundamentally improved, the core defect of horizontal pouring is effectively overcome, meanwhile, the production efficiency and economic benefits are improved, and the manufacturing requirements for high quality and low cost of brake discs of engineering trucks are met.

Description

Technical Field

[0001] This utility model relates to the field of mold manufacturing technology, and in particular to a tilting engineering vehicle brake disc casting mold device. Background Technology

[0002] In the braking system of engineering vehicles, the brake disc is a core safety component, and its surface quality directly affects braking performance and service life.

[0003] Currently, the horizontal parting casting process is widely used in the industry to produce brake discs for engineering vehicles. In this process, the sand box is placed horizontally, and molten iron is poured into the cavity from the side or bottom of the mold. However, horizontal casting presents two major technical problems:

[0004] 1. Surface depression: Due to the relatively thick local area of ​​the brake disc, the thick part of the local area leads to the formation of hot spots. When the molten iron shrinks during the cooling process, it is easy to form surface depression defects.

[0005] 2. Incomplete filling: When pouring molten iron horizontally, some deep cavities or distant areas are prone to defects such as missing edges or incomplete filling due to high resistance to molten iron flow and rapid cooling at the front end.

[0006] To address these issues, existing technologies primarily enhance feeding by increasing the number of risers and enlarging the cross-section of the ingate. However, such improvements are limited by the compact structure of the brake disc itself—risers must avoid critical areas such as the brake disc's mounting holes and cooling fins, resulting in limited space for their placement. This limits the improvement in feeding effectiveness, and the additional risers increase molten iron consumption. Furthermore, during horizontal pouring, the molten iron flow direction is perpendicular to the direction of gravity, making it difficult to achieve a "bottom-up" sequential solidification. The hot spot zone remains at the end of the feeding process, and the root cause of the defects remains unresolved. Utility Model Content

[0007] This utility model aims to solve the problems of surface depressions and / or incomplete filling in the existing technology. It optimizes the mold structure by optimizing the molten iron flow path and the feeding mechanism. The specific technical solution is as follows:

[0008] A tilting engineering vehicle brake disc casting mold device includes a sand box, a brake disc model and a gating system. Unlike the prior art, the brake disc model is tilted downwards at the far end away from the gating system.

[0009] Furthermore, the tilt angle of the brake disc model, that is, the angle between the brake disc model surface and the horizontal plane, is 1°-5°.

[0010] Furthermore, it also includes a template, a stop, and a process fixture. The upper and lower surfaces of the template and the stop, and the lower surface of the process fixture are parallel to the horizontal plane. The angle between the upper surface of the process fixture and the horizontal plane is equal to the tilt angle. The process fixture is fixed on the stop and supports the brake disc model. The stop is embedded in a groove opened in the template.

[0011] Furthermore, the process die and the stop are fixedly connected by positioning pins and bolts, and the number of positioning pins is 2-4, which are evenly distributed along the circumference of the stop.

[0012] Furthermore, the gating system includes a sprue, a gating cup, a left sprue, and a right sprue. The sprue is located at the 9 o'clock position of the brake disc model. The left sprue extends circumferentially along the brake disc model to the 12 o'clock position. The right sprue extends circumferentially along the brake disc model to a position between the 8 o'clock and 7 o'clock positions. Two ingates connect the left sprue to the brake disc model, and one ingate connects the right sprue to the brake disc model.

[0013] Furthermore, the riser is located at the junction of the right horizontal runner and the ingate.

[0014] Furthermore, the left and right horizontal runners are connected near the sprue by a sunken connecting channel, the bottom of which is lower than the bottom surface of the left or right horizontal runner, and the sunken depth is 5-15mm.

[0015] Furthermore, the lower end of the sprue extends downward to form a gate recess.

[0016] Furthermore, the ingate extends from the lower region to the higher region, and has a trapezoidal or circular cross-section with a cross-sectional area of ​​70 mm² to 700 mm².

[0017] Furthermore, the cross-sections of the left and right horizontal runners are trapezoidal, with the upper base width being 15-30mm, the lower base width being 20-40mm, and the height being 10-25mm. The cross-sectional area of ​​the left and right horizontal runners gradually decreases along the direction away from the sprue, with a reduction rate of 5%-15% / 100mm.

[0018] Compared with the prior art, the present invention has the following beneficial technical effects:

[0019] 1. Gravity-guided filling reduces incomplete filling defects. After the brake disc model is tilted, molten iron enters the mold cavity from the gating system and fills the mold sequentially from bottom to top under the action of gravity, preferentially filling the deep cavity and far-end areas, reducing the problem of incomplete filling caused by flow resistance, and reducing the incidence of defects such as edge missing parts.

[0020] 2. Reduce reliance on risers and increase yield. Gravity feeding efficiency is significantly improved by inclined casting, eliminating the need to increase the number of risers or enlarge the ingate cross-section. This reduces molten iron consumption, increases yield, and lowers material costs and production cycle.

[0021] 3. Strong process compatibility and wide adaptability. The tilt angle can be flexibly adjusted according to the thickness of the brake disc, making it suitable for casting brake discs of different specifications of engineering vehicles. It avoids the problem of feeding failure caused by differences in product structure, and its versatility is superior to traditional horizontal casting molds.

[0022] In summary, through the inclined structure design, this utility model fundamentally improves the filling and shrinkage effects of molten iron, effectively solves the core defects of horizontal casting, and at the same time improves production efficiency and economic benefits, meeting the manufacturing requirements of high-quality and low-cost brake discs for engineering vehicles. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of this utility model.

[0024] Figure 2 yes Figure 1 Top view.

[0025] Figure 3 yes Figure 2 Sectional view at point AA.

[0026] Figure 4 This is a schematic diagram of the structure of the brake disc model, template, stop, and process tire of this utility model. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings.

[0028] like Figure 1-4 The invention relates to a tilting engineering vehicle brake disc casting mold device, which includes a sand box, a brake disc model 100 and a gating system 200, wherein the brake disc model 100 is tilted downward at the far end away from the gating system 200.

[0029] When pouring brake discs for engineering vehicles horizontally, the molten iron needs to flow horizontally to fill the mold cavity. However, the distal and deeper areas are prone to incomplete filling due to higher flow resistance and faster cooling. This device tilts the distal end of the brake disc mold downwards, creating an inclined channel from low to high within the mold cavity. After entering from the lower section of the gating system, the molten iron fills the mold sequentially from bottom to top under gravity, preferentially filling the distal and deeper areas. Gravity partially offsets the flow resistance, maintaining the temperature at the front end of the molten iron and preventing problems such as edge defects or incomplete filling caused by delayed filling or excessively rapid cooling, thus reducing incomplete pouring defects.

[0030] During horizontal casting, feeding in the hot spot zone (locally thick areas) relies on side risers. This feeding path is long and structurally limited, requiring multiple risers with limited effectiveness and increased molten iron consumption. This device allows for direct and efficient feeding of molten iron to the hot spot zone. Gravity-driven feeding eliminates the need for excessive auxiliary risers, reducing the number and size of risers, minimizing molten iron waste, increasing yield, and avoiding feeding failure due to limited riser layout.

[0031] The device utilizes an adjustable support structure at the bottom of the sand box, allowing for flexible adjustment of the tilt angle based on factors such as brake disc thickness and hot spot location to accommodate the feeding requirements of products of different specifications. For example, a larger tilt angle can be used for thicker brake discs to enhance gravity feeding, while a smaller angle can be used for thinner products to prevent molten iron from eroding the mold cavity. Furthermore, the gating system employs a modular layout, with horizontal runners distributed circumferentially and connected via sunken channels. The number and position of ingates can be adjusted adaptively. Combined with a detachable process jig structure, it can adapt to symmetrical or asymmetrical brake disc structures of varying complexity without significant mold modifications, enhancing the process's compatibility with diverse products and production flexibility.

[0032] In another preferred embodiment, the tilt angle of the brake disc model 100, i.e., the angle α between the brake disc model surface and the horizontal plane, is 1°-5°. By limiting the tilt angle of the brake disc model to 1°-5°, the driving effect of gravity on the filling and shrinkage of molten iron can be precisely balanced. When the angle is too small (<1°), the effect of gravity is not obvious, and when the angle is too large (>5°), it may cause molten iron to splash and scour the cavity wall, resulting in sand holes. This range has been verified in practice to both utilize gravity to guide molten iron to fill the mold from bottom to top and prevent uneven stress on the mold caused by excessive tilting, making it suitable for the structural dimensions of most engineering vehicle brake discs.

[0033] In another preferred embodiment, the system further includes a mold plate 1, a stop 2, and a process fixture 3. The upper and lower surfaces of the mold plate 1 and the stop 2, and the lower surface of the process fixture 3, are parallel to the horizontal plane. The angle between the upper surface of the process fixture 3 and the horizontal plane is equal to the tilt angle. The process fixture 3 is fixed to the stop 2 and supports the brake disc model 100. The stop 2 is embedded in a groove in the mold plate 1. Through the cooperation of the mold plate, the stop 2, and the process fixture, a stable tilt angle positioning system is constructed. The angle between the upper surface of the process fixture and the horizontal plane is equal to the tilt angle, ensuring that the brake disc model is fixed at the designed angle and avoiding manual adjustment errors. The stop 2 is embedded in the groove of the mold plate, allowing for quick disassembly and replacement of the process fixture to adapt to different tilt angle requirements. At the same time, the stop 2 structure provides lateral positioning to prevent the mold from shifting during the casting process.

[0034] In another preferred embodiment, the process die 3 and the stop 2 are fixedly connected by locating pins and bolts. The number of locating pins is 2-4, and they are evenly distributed circumferentially along the stop 2. Using a combination of 2-4 evenly distributed locating pins and bolts enhances the mold assembly accuracy and structural strength. The locating pins ensure that the angular reference of the process die and the stop is consistent, avoiding changes in the filling path due to installation deviations. The evenly distributed bolts provide symmetrical clamping force, resisting the buoyancy impact of molten iron during pouring, preventing dynamic changes in the tilt angle, and ensuring the stability of the feeding channel.

[0035] In another preferred embodiment, the gating system 200 includes a sprue 201, a gating cup 202, a left runner 203, and a right runner 204. The sprue 201 is located at the 9 o'clock position of the brake disc model 100. The left runner 203 extends circumferentially along the brake disc model 100 to the 12 o'clock position. The right runner 204 extends circumferentially along the brake disc model 100 to a position between the 8 o'clock and 7 o'clock positions. Two ingates 205 connect the left runner 203 to the brake disc model 100, and one ingate 205 connects the right runner 204 to the brake disc model 100. The sprue is located at the 9 o'clock position, and the left and right sprues extend to the 12 o'clock and 8-7 o'clock positions respectively. With a 2:1 ratio of sprues, asymmetric filling optimization is achieved: For the asymmetric structure that may exist in the brake disc (such as a thick hot spot on one side), the layout of double sprues on the left and single sprues on the right prioritizes filling the left side where the hot spot is concentrated, balancing the supply of molten iron in different areas; circumferential uniform coverage: The sprues extend more than a semicircle along the circumference (9 o'clock to 12 o'clock, 9 o'clock to 7 o'clock), ensuring that molten iron can fill the cavity from multiple directions, reducing flow dead zones, which is especially suitable for brake disc structures with complex heat dissipation fins or mounting holes.

[0036] In another preferred embodiment, the riser 300 is located at the junction of the right horizontal runner 204 and the ingate 205. Positioning the riser at the junction of the end of the right horizontal runner and the ingate precisely matches the distribution of hot spots. This position, as the highest point, allows for gravity feeding via the shortest path, reducing the flow resistance of molten iron in the feeding channel. By directly setting the riser at the intersection of the horizontal runner and the ingate, there is no need to add an additional auxiliary feeding channel, simplifying the mold structure and reducing molten iron consumption.

[0037] In another preferred embodiment, the left horizontal sprue 203 and the right horizontal sprue 204 are connected near the sprue 201 by a sunken connecting channel 206. The bottom of the sunken connecting channel 206 is lower than the bottom surface of the left horizontal sprue 203 or the right horizontal sprue 204, and the sunken depth is 5-15mm. The left / right horizontal sprues are connected by a connecting channel with a bottom sunken by 5-15mm, which optimizes the flow characteristics of molten iron in the gating system. ① Dynamic pressure balance: The sunken structure allows the molten iron from the two horizontal sprues to converge at a lower point, avoiding pressure differences caused by excessively fast filling on one side, and preventing molten iron from backflowing or splashing from one side of the ingate; ② Slag collection and venting: The sunken area can retain impurities (such as oxide scale) during the pouring process, while providing an escape path for gas in the mold cavity, reducing defects such as slag inclusions and porosity.

[0038] In another preferred embodiment, the lower end of the sprue 201 extends downward to form a gating recess 207. The gating recess, formed by the extension of the sprue end, optimizes the transition of molten iron from the ladle to the mold. As an expansion space before the molten iron enters the runner, the gating recess can mitigate the turbulence caused by the high-speed impact of the molten iron, preventing sand-bursting defects (such as molding sand falling into the mold cavity). By expanding the local cross-sectional area, the molten iron is temporarily retained within the gating recess, evenly distributed to the left / right runners, ensuring consistent filling speeds on both sides of the ingate.

[0039] In another preferred embodiment, the ingate 205 extends from the lower to the higher region, with a trapezoidal or circular cross-section and a cross-sectional area ranging from 70 mm² to 700 mm². The ingate's trapezoidal or circular cross-section, covering a wide range of cross-sectional areas, enhances process adaptability. Shape adaptability: A circular cross-section offers low flow resistance, suitable for high-flow-rate filling requirements; a trapezoidal cross-section allows adjustment of the upper / lower base width to change the molten iron's rising angle, adapting to the flow characteristics of inclined cavities; the cross-sectional area covers from 70 mm² (small brake disc) to 700 mm² (large thick-walled brake disc), allowing for rapid adaptation to different tonnages of molten iron pouring by replacing ingate modules of different specifications, avoiding insufficient filling or waste due to a fixed cross-section.

[0040] In another preferred embodiment, the cross-sections of the left and right horizontal runners 203 and 204 are trapezoidal, with the upper base width being 15-30mm, the lower base width being 20-40mm, and the height being 10-25mm. The cross-sectional area of ​​the left and right horizontal runners gradually decreases along the direction away from the sprue 201, with a reduction rate of 5%-15% / 100mm. The lower base width being greater than the upper base increases the contact area between the molten iron and the mold wall, slowing down the cooling rate of the upper layer of molten iron and maintaining overall fluidity. The further away from the sprue, the smaller the cross-sectional area of ​​the horizontal runner, which forces the molten iron to flow preferentially towards the far end of the ingate, avoiding backflow of molten iron due to excessive pressure in the near end of the ingate. This also reduces molten iron retention at the end of the horizontal runner, reducing the burden on the riser for feeding.

[0041] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A tilting engineering vehicle brake disc casting mould arrangement comprising a flask, a brake disc pattern (100) and a gating system (200), characterized in that, The brake disc model (100) is tilted downward at the far end away from the gating system (200).

2. The sloped engineering vehicle brake disc pouring mold apparatus of claim 1, wherein, The tilt angle of the brake disc model (100), that is, the angle (a) between the brake disc model surface and the horizontal plane, is 1°-5°.

3. The sloped engineering vehicle brake disc pouring mold apparatus of claim 1, wherein, It also includes a mold plate (1), a stop (2) and a process tire (3). The upper and lower surfaces of the mold plate (1) and the stop (2) and the lower surface of the process tire (3) are parallel to the horizontal plane. The angle between the upper surface of the process tire (3) and the horizontal plane is equal to the tilt angle. The process tire (3) is fixed on the stop (2) and supports the brake disc model (100). The stop (2) is embedded in the groove opened in the mold plate (1).

4. The sloped engineering vehicle brake disc pouring mold apparatus of claim 3, wherein, The process kit (3) and the stop (2) are fixedly connected by positioning pins and bolts. The number of positioning pins is 2-4, and they are evenly distributed along the circumference of the stop (2).

5. The sloped engineering vehicle brake rotor pouring mold apparatus of claim 1, wherein, The gating system (200) includes a sprue (201), a pouring cup (202), a left runner (203), and a right runner (204). The sprue (201) is located at the 9 o'clock position of the brake disc model (100). The left runner (203) extends circumferentially along the brake disc model (100) to the 12 o'clock position. The right runner (204) extends circumferentially along the brake disc model (100) to a position between the 8 o'clock and 7 o'clock positions. Two ingates (205) connect the left runner (203) to the brake disc model (100), and one ingate (205) connects the right runner (204) to the brake disc model (100).

6. The sloped engineering vehicle brake disc pouring mold apparatus of claim 5, wherein, The riser (300) is located at the junction of the right horizontal runner (204) and the ingate (205).

7. The sloped engineering vehicle brake disc pouring mold apparatus of claim 5, wherein, The left horizontal runner (203) and the right horizontal runner (204) are connected by a sunken connecting channel (206) near the straight runner (201). The bottom of the sunken connecting channel (206) is lower than the bottom surface of the left horizontal runner (203) or the right horizontal runner (204), and the sunken depth is 5-15mm.

8. The sloped engineering vehicle brake disc pouring mold apparatus of claim 5, wherein, The lower end of the sprue (201) extends downward to form a sprue socket (207).

9. The sloped engineering vehicle brake disc pouring mold apparatus of claim 5, wherein, The ingate (205) extends from the lower region to the higher region, and has a trapezoidal or circular cross-section with a cross-sectional area of ​​70 mm² to 700 mm².

10. The sloped engineering vehicle brake disc pouring mold apparatus of claim 5, wherein, The cross-sections of the left horizontal runner (203) and the right horizontal runner (204) are trapezoidal, with the upper base width being 15-30mm, the lower base width being 20-40mm, and the height being 10-25mm. The cross-sectional area of ​​the left and right horizontal runners gradually decreases along the direction away from the sprue (201), with a reduction rate of 5%-15% / 100mm.

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