A gating system capable of effectively eliminating the shrinkage of the cylinder head of a brake caliper body

Abstract

This utility model relates to the field of casting technology, specifically to a gating system for effectively eliminating shrinkage porosity in the cylinder head of a brake caliper. The system includes: a gating cup, a sprue, a runner, and a riser. The runner is connected to the sprue. A filter screen is fixedly installed inside the sprue. A conformal insulating block is provided on the runner, positioned in the hot spot area of ​​the oil inlet boss in the cylinder head. The shape of the insulating block matches the contour of the hot spot area. The conformal insulating block is connected to the riser through a feeding channel, which provides directional and sequential solidification feeding to the hot spot area via the feeding channel. This utility model optimizes the molten iron flow direction and feeding channel design, resulting in a dense cylinder head structure, reducing the shrinkage porosity defect rate to 0%, and eliminating the need for chilling processes. This significantly reduces manufacturing costs and avoids porosity and carbide defects, making it suitable for the casting production of high-precision brake calipers.

Description

Technical Field

[0001] This utility model relates to the field of casting technology, specifically to a gating system that effectively eliminates shrinkage and loosening of the brake caliper cylinder head. Background Technology

[0002] The cylinder head of the brake caliper in passenger vehicles requires a dense internal structure due to high-pressure operating conditions. If shrinkage porosity exists, it can lead to hydraulic oil leakage and brake failure. Due to the limitations of the caliper design structure, effective shrinkage compensation is not possible. In the existing technology, casting engineers mostly use chilling process to compensate for shrinkage, but this has the following problems: additional sandbag iron or sand core assembly of chills is required, increasing manufacturing costs; chills are prone to rusting, causing subcutaneous porosity, and the quenching of molten iron generates carbides, affecting material properties; the shrinkage compensation effect is unstable and it is difficult to completely eliminate shrinkage porosity.

[0003] Therefore, there is an urgent need for a low-cost, high-reliability casting system to solve the above problems. Utility Model Content

[0004] The purpose of this invention is to provide a casting system that effectively eliminates shrinkage in the cylinder head of the brake caliper. By optimizing the flow direction of molten iron and the design of the feeding channel, the shrinkage defect in the cylinder head of the brake caliper is eliminated, production costs are reduced, and the side effects of the chilling process are avoided.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a casting system for effectively eliminating shrinkage of the brake caliper cylinder head, comprising: a gating cup, a sprue, a runner, and a riser. The runner is connected to the sprue. A filter screen is fixedly installed inside the sprue. A conformal heat-insulating block is provided on the runner, and the conformal heat-insulating block is located in the hot spot area of ​​the oil inlet boss of the caliper cylinder head. Its shape matches the contour of the hot spot area, and the conformal heat-insulating block is connected to the riser through a shrinkage compensation channel. The riser performs directional and sequential solidification and shrinkage compensation of the hot spot area through the shrinkage compensation channel.

[0006] Preferably, the filter screen is made of a high-temperature resistant ceramic material, the composition of which is zirconium oxide (ZrO2), with a pore size of 2.0 mm and a temperature resistance range of 1600-1700℃.

[0007] Preferably, the conformal insulating block maintains its own temperature by absorbing heat from the molten iron.

[0008] Preferably, the feeding channel is a directional channel connecting the conformal insulation block and the riser.

[0009] Preferably, the filter screen is located before the flow splits from the sprue to the transverse sprue, and its installation direction is perpendicular to the flow direction of the molten iron.

[0010] Compared with the prior art, this utility model provides a casting system that effectively eliminates shrinkage porosity in the cylinder head of the brake caliper, and has the following beneficial effects: the molten iron is filled smoothly without slag or air entrapment; the cylinder head structure is dense, and the shrinkage porosity defect rate is reduced to 0%; no chilling process is required, reducing manufacturing costs and avoiding defects such as porosity and carbides. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the casting system structure of this utility model;

[0012] Figure 2 This utility model Figure 1 Enlarged view of point A in the middle;

[0013] Figure 3 This is an illustration of the effect of a non-conformal thermal insulation block;

[0014] Figure 4 This is a rendering of the conformal insulation block of this utility model.

[0015] Explanation of the attached diagram labels: 1. Slurry cup; 2. Straight pouring line; 3. Filter screen; 4. Horizontal pouring line; 5. Irregularly shaped insulation block; 6. Riser. Detailed Implementation

[0016] The technical solutions of the present utility model will now be described with reference to the accompanying drawings in the embodiments of the present utility model:

[0017] This embodiment uses passenger car brake caliper cylinder head casting as an application scenario, but the technical solution of this utility model is also applicable to the production of other castings that require high density.

[0018] like Figure 1-2 As shown, this utility model provides a casting system that effectively eliminates shrinkage of the brake caliper cylinder head, including: a pouring cup 1, a straight sprue 2, a horizontal sprue 4, a conformal insulating block 5, and a riser 6.

[0019] The pouring cup 1 serves as the initial container for molten iron. Its flared mouth is designed to reduce splashing and improve pouring accuracy. The inner wall of the pouring cup 1 is treated with a refractory coating, and its volume is designed to be 5-10L based on the weight of the casting, ensuring a continuous and stable flow of molten iron into the sprue 2.

[0020] Molten iron is first poured into the sprue 1 and then enters the sprue 2 by gravity. The sprue 2 has a circular cross-section and smooth inner walls to reduce flow resistance. Its bottom is connected to the runner 4 by an arc transition to prevent the molten iron from turning sharply and causing turbulence.

[0021] A filter screen 3 is fixedly installed inside the sprue 2. The filter screen 3 is made of high-temperature resistant ceramic material, specifically zirconium oxide (ZrO2). Its dimensions are 50mm × 50mm × 12.5mm, with a pore size of 2.0mm, and a temperature resistance range of 1600-1700℃. The filter screen 3 is located before the sprue 2 branches off to the grate 4, and its installation direction is perpendicular to the flow direction of the molten iron. It is used to filter slag from the molten iron and ensure stable flow, preventing air and slag entrapment caused by turbulence.

[0022] The horizontal sprue 4 is connected to the vertical sprue 2 and is used to guide the flow of molten iron to ensure smooth filling.

[0023] A conformal heat-insulating block 5 is installed in the hot spot area of ​​the oil inlet boss in the cylinder head of the clamp body. The conformal heat-insulating block 5 has a size of 30mm×15mm×10mm, and its shape matches the contour of the hot spot area. The conformal heat-insulating block 5 maintains its own temperature by absorbing the heat of the molten iron, thus delaying the solidification time of the hot spot area.

[0024] The conformal insulation block 5 is connected to the riser 6 through the feeding channel. The high-temperature molten iron stored in the riser 6 is continuously fed to the hot spot area through the feeding channel, realizing the sequential solidification of "hot spot area → feeding channel → riser" and completely eliminating shrinkage defects.

[0025] like Figure 3 As shown, there is no conformal insulation block 5 within the red box. The hot spot area → feeding channel → riser solidify out of sequence. The feeding channel is disconnected, and shrinkage porosity will occur in the disconnected hot spot area.

[0026] like Figure 4 As shown, the green box contains a conformal insulation block 5. Solidification occurs sequentially from the hot spot area to the feeding channel to the riser, preventing shrinkage porosity.

[0027] Process flow and working principle

[0028] Iron pouring and purification: Molten iron enters the straight pouring channel 2 through the soup cup 1, and is filtered by the filter screen 3 to filter the slag and stabilize the flow rate, forming a smooth flow without turbulence.

[0029] Temperature control in the hot spot zone: After the molten iron enters the mold cavity through the horizontal gating channel 4, the conformal heat preservation block 5 absorbs the heat of the molten iron to maintain the temperature of the hot spot zone and ensure that it solidifies later than the surrounding area.

[0030] Sequential solidification and feeding: During solidification, a directional temperature gradient is formed between the hot spot zone, the feeding channel, and riser 6. The high-temperature molten iron in riser 6 continuously feeds the solidification shrinkage gaps in the hot spot zone, completely eliminating shrinkage defects.

[0031] During the casting process, the molten iron is purified and stabilized before being smoothly filled into the mold. The conformal insulation block 5 and the feeding channel work together to maintain the temperature of the hot spot area, and the riser 6 fills the solidification shrinkage gap through directional feeding.

[0032] The final casting cylinder head has a dense structure. Industrial CT testing showed that the density of the cylinder head structure was significantly improved, the shrinkage porosity defect rate was reduced to 0%, and the use of chill iron process was not required, thus avoiding subcutaneous porosity and carbide defects.

[0033] Scope of application: This solution is not only applicable to brake caliper bodies for passenger vehicles, but can also be extended to the production of other high-density castings (such as hydraulic valve bodies and engine cylinder heads).

[0034] The innovative points of this utility model

[0035] Vertical filter installation design: Breaking through the traditional horizontal installation method, it combines high-temperature resistant ceramic material to achieve the dual functions of molten iron purification and flow stabilization.

[0036] Conformal insulation blocks are matched to hot spots: through precise design of shape and size, the shrinkage compensation channel is opened to ensure sequential solidification.

[0037] Riser-directed feeding mechanism: Combined with temperature control in the hot spot zone, it achieves efficient feeding in a chillless process.

[0038] This invention optimizes the flow direction of molten iron and the design of the feeding channel, making the cylinder head structure dense and reducing the shrinkage defect rate to 0%. It also eliminates the need for chilling processes, significantly reducing manufacturing costs and avoiding defects such as porosity and carbides. It is suitable for casting production of high-precision brake caliper bodies.

[0039] The above embodiments are merely some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

Claims

1. A casting system for effectively eliminating shrinkage of the brake caliper cylinder head, comprising a gating cup (1), a sprue (2), a runner (4), and a riser (6), wherein the runner (4) is connected to the sprue (2), characterized in that: A filter screen (3) is fixedly installed inside the sprue (2), and a conformal heat-insulating block (5) is provided on the sprue (4). The conformal heat-insulating block (5) is located in the hot spot area of ​​the oil inlet boss of the cylinder head of the clamp body. Its shape matches the outline of the hot spot area. The conformal heat-insulating block (5) is connected to the riser (6) through the feeding channel. The riser (6) performs directional sequential solidification feeding of the hot spot area through the feeding channel.

2. The casting system for effectively eliminating brake caliper cylinder head shrinkage according to claim 1, characterized in that: The filter screen (3) is made of high-temperature resistant ceramic material, which is composed of zirconium oxide (ZrO2), has a pore size of 2.0 mm, and a temperature range of 1600-1700℃.

3. The casting system for effectively eliminating brake caliper cylinder head shrinkage according to claim 1, characterized in that: The conformal heat-insulating block (5) maintains its own temperature by absorbing the heat of molten iron.

4. The casting system for effectively eliminating brake caliper cylinder head shrinkage according to claim 1, characterized in that: The feeding channel is a directional channel connecting the conformal insulation block (5) and the riser (6).

5. The casting system for effectively eliminating brake caliper cylinder head shrinkage according to claim 1, characterized in that: The filter screen (3) is located before the sprue (2) splits into the grate (4), and its installation direction is perpendicular to the direction of molten iron flow.

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