A casting mold for solving the gating material defect of automobile brake caliper

Abstract

The utility model belongs to the field of automobile brake caliper casting technology, especially a kind of casting mould for solving the gate material defect of automobile brake caliper, including mould cavity, the mould cavity is internally provided with brake caliper casting cavity that is set as two rows two columns left and right mirror image symmetry;Gate cup, cross gate A, cross gate B, vertical gate, avoid slag sheet A, avoid slag sheet B, riser and brake caliper cavity are provided in the mould cavity;Gate cup is set on the center above mould cavity, and horizontal arrangement cross gate A is symmetrically set in the two sides of gate cup.The utility model is improved by being provided with fracture groove at the junction of riser and brake caliper casting cavity, and brake caliper gate material problem can be effectively reduced, so that the residual at pouring riser is not polished, acceptance requirement can be reached, process yield can be effectively improved and production efficiency can be effectively improved, and the risk of shrinkage defect is reduced.

Description

Technical Field

[0001] This utility model belongs to the field of automotive brake caliper casting technology, and in particular relates to a casting mold that solves the defect of insufficient material at the gate of automotive brake calipers. Background Technology

[0002] As is widely known, brake calipers are a crucial component of a car's braking system. A malfunction in a brake caliper can significantly impact driving safety. Brake calipers are clamp-like devices that decelerate, stop, or maintain a stopped state of the moving wheels, and are generally used only in disc brake systems. Brake calipers are also considered exterior automotive parts; a shortage of materials not only affects the aesthetics but also impacts product quality, reduces the yield rate of castings, and increases costs.

[0003] In current foundry industry practice, to effectively avoid material shortages in castings caused by material residue at the gating gate, a common process solution is to place the gating fracture groove far from the main casting body. However, in-depth production practice and process analysis have revealed two significant drawbacks to this seemingly conventional approach. First, placing the gating fracture groove far from the main casting body directly leads to a significant increase in the amount of material remaining after casting. In subsequent casting processing, these remaining gating portions require additional grinding. Due to the large amount of residue, grinding is not only time-consuming and labor-intensive but also requires more manpower and equipment resources. This undoubtedly increases the workload of the entire production process, and the reduced production efficiency directly affects product delivery time and market responsiveness, thereby increasing the company's operating costs, including labor costs, equipment depreciation costs, and other potential costs arising from extended production cycles. Secondly, the design of the gate fracture groove being far from the main body of the casting, from a thermodynamic perspective, will increase the hot spot area inside the part. The hot spot is a local high-temperature area formed during the solidification process of the casting due to uneven cooling rate. This area is prone to shrinkage stress concentration. As the hot spot area increases, the risk of shrinkage porosity defects inside the casting will also increase accordingly. Shrinkage porosity defects will not only affect the appearance quality of the casting, but also seriously weaken the mechanical properties of the casting, such as strength and toughness, thereby reducing the overall quality and reliability of the casting and posing potential hazards to the safety of product use. Utility Model Content

[0004] The purpose of this invention is to propose a casting mold that solves the problem of insufficient material in the gate of automotive brake calipers. This mold can effectively improve the process yield and production efficiency, reduce the risk of shrinkage defects, and reduce operating costs while improving production efficiency.

[0005] The present invention adopts the following technical solution: A casting mold for solving the defect of insufficient material at the gate of automotive brake calipers includes a mold cavity, wherein the mold cavity is a brake caliper casting cavity arranged in two rows and two columns of left-right mirror symmetrical arrangement; the mold cavity is provided with a pouring cup, a transverse sprue A, a transverse sprue B, a longitudinal sprue, a slag-avoiding sheet A, a slag-avoiding sheet B, a riser, and the brake caliper cavity; the pouring cup is located above the center of the mold cavity, and transverse sprues A are symmetrically arranged on both sides of the pouring cup; the front end of the transverse sprue A... Each of the above is provided with a horizontal sprue B connected to it. The lower end of the horizontal sprue A is connected to a vertical sprue. The connecting end of the vertical sprue is provided with evenly distributed risers. A slag-avoiding sheet A is also provided at the junction of the horizontal sprue A and the horizontal sprue B. A slag-avoiding sheet B is also provided at the junction of the horizontal sprue A and the vertical sprue at the riser. The other end of the riser is provided with a brake caliper casting cavity connected to its inner side, and a fracture groove is provided at the junction of the riser and the brake caliper casting cavity.

[0006] The bottom of the fracture groove is 1.5 mm away from the cavity of the brake caliper casting.

[0007] The fracture groove is not made parallel to the plane of the brake caliper casting cavity, but is formed by a 6° draft angle away from the caliper body to create an oblique fracture groove.

[0008] The pouring cup is a funnel-shaped structure that is axially cut open.

[0009] The center lines of the two columns of casting cavities coincide with the center line of the pouring cup.

[0010] Through the implementation of this utility model, good usage results have been achieved: The casting mold of this utility model, by setting a fracture groove at the junction of the riser and the brake caliper casting cavity, can effectively reduce the problem of insufficient material at the gate of the brake caliper. The residue at the gate does not need to be polished to meet the acceptance requirements. It can effectively improve the process yield and production efficiency, reduce the risk of shrinkage defects, and reduce operating costs while improving production efficiency. It lays a solid foundation for the mass production of high-quality automotive brake calipers in the future. Attached Figure Description

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

[0012] Figure 2 yes Figure 1 Enlarged view of point A in the image.

[0013] Figure 3 yes Figure 2 A top-down view of the component at the medium magnification.

[0014] In the diagram: 1. Sprue cup, 2. Horizontal runner A, 3. Horizontal runner B, 4. Longitudinal runner, 5. Slag-avoiding sheet A, 6. Slag-avoiding sheet B, 7. Riser, 8. Brake caliper cavity, 9. Fracture groove. Detailed Implementation

[0015] The present invention will be described in conjunction with the accompanying drawings.

[0016] like Figures 1-3 This invention discloses a casting mold for solving the defect of insufficient material at the gate of an automotive brake caliper. The mold includes a mold cavity, which is a brake caliper casting cavity arranged in two rows and two columns, mirror-symmetrically. The mold cavity contains a pouring cup 1, a horizontal sprue A2, a horizontal sprue B3, a vertical sprue 4, slag-avoiding sheets A5 and B6, a riser 7, and a brake caliper cavity 8. The pouring cup 1 is located above the center of the mold cavity and is an axially sectionalized funnel-shaped structure. This funnel-shaped design effectively counteracts turbulence and molten metal splashing during pouring. The centerlines of the two columns of casting cavities coincide with the centerline of the pouring cup 1. Horizontally arranged horizontal sprues A2 are symmetrically arranged on both sides of the pouring cup 1. A horizontal sprue B3 is connected to the lower front end of each horizontal sprue A2, and a vertically arranged vertical sprue 4 is connected to the lower end of each horizontal sprue A2. The connecting end of the gating system 4 is provided with evenly distributed risers 7; the risers 7 are used to connect the pouring system to the molten iron and for feeding; a slag-avoiding sheet A5 is also provided at the junction of the horizontal gating system A2 and the horizontal gating system B3; a slag-avoiding sheet B6 is also provided at the junction of the horizontal gating system A2 and the vertical gating system 4 at the riser 7; the slag-avoiding sheets A5 and B6 can block slag and also slow down the flow rate and turbulence of the molten iron, so that clean and stable molten iron flows downward into the horizontal gating system and the riser 7; the other end of the riser 7 is provided with a brake caliper casting cavity 8 connected to its inner side, and a fracture groove 9 is provided at the junction of the riser 7 and the brake caliper casting cavity 8; the bottom of the fracture groove 9 is 1.5 mm away from the brake caliper casting cavity 8; the fracture groove 9 is not made parallel to the plane of the brake caliper casting cavity 8, but is drawn away from the caliper body at a 6° angle to form an oblique fracture groove.

[0017] In operation, molten iron enters the horizontal runner A2 through the pouring cup 1 and then flows through slag-avoiding plates A and B into the riser 7, horizontal runner B3, and vertical runner 4, respectively. Finally, the molten iron enters each brake caliper cavity 8 through the heat-insulating riser 7. A fracture groove 9 is provided at the junction of the riser 7 and the brake caliper casting cavity 8. The fracture groove 9 is not parallel to the plane of the brake caliper cavity 8, but forms an oblique fracture groove at a 6° angle away from the caliper body. At this time, the top of the pouring cup is 1.8mm away from the part. When separating the riser 7, the hydraulic shear applies opposing forces to the riser 7 and the part along the gap between the riser 7 and the part. Due to the existence of the 6° angle of the fracture groove, the fracture position is offset away from the part. Even if there is a material shortage defect, the material shortage will occur outside the part body and will not extend into the part body. This can effectively reduce the problem of material shortage at the brake caliper pouring cup, so that the residue at the pouring cup and riser does not need to be polished to meet the acceptance requirements. This can effectively improve the process yield and production efficiency, and reduce the risk of shrinkage defects.

[0018] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various equivalent modifications can be made to the technical solution of the present invention, and all such equivalent modifications fall within the protection scope of the present invention.

Claims

1. A casting mold for solving the defect of insufficient material in the gate of automotive brake calipers, characterized in that: The mold cavity includes a mold cavity, which is a brake caliper casting cavity arranged in two rows and two columns of mirror images symmetrically arranged inside the mold cavity; the mold cavity is provided with a pouring cup (1), a horizontal runner A (2), a horizontal runner B (3), a vertical runner (4), a slag-avoiding sheet A (5), a slag-avoiding sheet B (6), a riser (7), and a brake caliper cavity (8); the pouring cup (1) is located above the center of the mold cavity, and horizontal runners A (2) are arranged symmetrically on both sides of the pouring cup (1); a horizontal runner B is provided below the front end of each horizontal runner A (2) and communicates with it. (3) The end of the horizontal gating A (2) is connected to a vertical gating (4) that is perpendicular to it; the connecting end of the vertical gating (4) is provided with evenly distributed risers (7); a slag-avoiding sheet A (5) is also provided at the junction of the horizontal gating A (2) and the horizontal gating B (3); a slag-avoiding sheet B (6) is also provided at the junction of the horizontal gating A (2) and the vertical gating (4) at the riser (7); the other end of the riser (7) is provided with a brake caliper casting cavity connected to its inner side, and a fracture groove (9) is provided at the junction of the riser (7) and the brake caliper casting cavity.

2. The casting mold for solving the defect of insufficient material in the gate of automotive brake calipers according to claim 1, characterized in that: The bottom of the fracture groove (9) is 1.5 mm away from the cavity of the brake caliper casting.

3. The casting mold for solving the defect of insufficient material in the gate of automotive brake calipers according to claim 1, characterized in that: The fracture groove (9) is not made parallel to the plane of the brake caliper casting cavity, but is formed by a 6° draft angle away from the caliper body to form an oblique fracture groove (9).

4. The casting mold for solving the defect of insufficient material in the gate of automotive brake calipers according to claim 1, characterized in that: The pouring cup (1) is a funnel-shaped structure that is axially cut open.

5. The casting mold for solving the defect of insufficient material in the gate of automotive brake calipers according to claim 1, characterized in that: The center lines of the two columns of casting cavities coincide with the center line of the pouring cup (1).

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