A novel brake disc casting structure for improving product quality

Abstract

This utility model relates to the field of casting systems, specifically disclosing a novel brake disc casting structure for improving product quality. It includes a pouring cup, a first horizontal sprue, a second horizontal sprue, four branch lines, two separate water inlets, a lower mold inlet, an upper mold inlet, a lower mold casting, and an upper mold casting. In traditional casting processes, the upper and lower mold inlets are opposite each other at an angle of approximately 120°. This process concentrates heat during casting, easily leading to uneven hardness. The improved simultaneous upper and lower mold water inlet design distributes the inlets, with an interval of approximately 60° between them. This design disperses heat during casting, ensuring uniform hardness differences in the product.

Description

Technical Field

[0001] This utility model relates to the field of casting systems, and specifically to a novel brake disc casting structure for improving product quality. Background Technology

[0002] With the continuous development of my country's casting industry, competition among foundries and the increasing demands from high-end customers for both the external and internal quality of castings, our casting processes must meet customer needs, requiring more professional and meticulous technical design. Brake discs are key components in vehicle braking systems, demanding high standards for both appearance and internal quality, necessitating continuous product optimization. Current brake disc casting technology often employs a double-layer process, where the upper mold is filled first, followed by the lower mold. This can lead to turbulence, air entrapment, and slag inclusions, resulting in defects such as sand holes and porosity. Internally, the process of filling the lower mold first, followed by the upper mold, results in inconsistent cooling and temperature fields between the upper and lower molds, leading to poor uniformity of casting hardness and unsatisfactory stability, especially noticeable in large-diameter castings. Brake disc hardness is also an important factor in ensuring stable braking of a vehicle. If the hardness is uneven, the brake disc will wear unevenly, resulting in reduced braking force and brake vibration and abnormal noise. Utility Model Content

[0003] A novel brake disc casting structure for improving product quality includes a pouring cup (1), a first horizontal runner (2), four branch runners (3), a lower mold water inlet plate (4), an upper mold casting (5), a lower mold casting (6), an upper mold water inlet plate (7), a second horizontal runner (8), and a water inlet plate (9). The pouring cup (1) is placed above the first horizontal runner (2), and two sets of water inlets (9) are installed on each side of the four branch runners (3).

[0004] Preferably, the pouring cup (1), the first horizontal runner (2), the four branch runners (3), the second horizontal runner (8), and the water inlet plate (9) are integrally formed by casting.

[0005] Preferably, the water inlet plate (9) includes a lower water inlet plate (4) and an upper water inlet plate (7).

[0006] Preferably, the upper casting (5) and the lower casting (6) are respectively placed inside the upper water inlet plate (7) and the lower water inlet plate (4).

[0007] Preferably, the lower water inlet plate (4) and the upper water inlet plate (7) include the lower water inlet cross-sectional area (401), the lower water inlet plate size (402), the upper water inlet cross-sectional area (701), and the upper water inlet plate size (702).

[0008] Compared with the prior art, the beneficial effects of this utility model are as follows: In traditional casting processes, the sprues of the upper and lower molds are opposite each other at an angle of approximately 120°. This method concentrates heat during casting, easily leading to uneven hardness. The improved simultaneous sprue entry system, however, uses dispersed sprues with an interval of approximately 60° between them. This disperses heat during molten iron entry, ensuring uniform hardness in the product. This invention, by controlling the flow rate and time of the molten iron entry into the upper and lower molds, ensures stable and consistent molten iron entry speed, preventing defects such as turbulence, air entrapment, and slag inclusions. Simultaneous molten iron entry into the upper and lower molds guarantees a consistent pouring temperature, thus ensuring stable and uniform hardness in the product. Attached Figure Description

[0009] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a partial structural diagram of the present invention; Figure 3 This is a partial structural diagram of the present invention; Figure 4 This is a partial structural diagram of the present invention; Figure 5 This is a partial structural diagram of the present invention; Figure 6 This is a partial structural diagram of the present invention; Figure 7 This is a schematic diagram of the structure of this utility model from various angles; Figure 8 This is a schematic diagram of the existing overall structure from different angles. Figure 9 This is a schematic diagram of the existing overall structure.

[0010] In the diagram: 1. Pour cup, 2. Streamer 1, 3 and 4 branch lines, 4. Lower mold inlet plate, 401. Cross-sectional area of ​​lower mold inlet, 402. Dimensions of lower mold inlet plate, 5. Upper mold casting, 6. Lower mold casting, 7. Upper mold inlet plate, 701. Cross-sectional area of ​​upper mold inlet, 702. Dimensions of upper mold inlet plate, 8. Streamer 2, 9. Inlet plate. Detailed Implementation

[0011] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0012] Example: Figures 1-7 As shown, this utility model discloses a novel brake disc casting structure for improving product quality, comprising a pouring cup (1), a first horizontal sprue (2), four branch channels (3), a lower mold water inlet plate (4), an upper mold casting (5), a lower mold casting (6), an upper mold water inlet plate (7), a second horizontal sprue (8), and water inlets (9). The pouring cup (1) is placed above the first horizontal sprue (2), and two sets of water inlets (9) are installed on each side of the four branch channels (3). The pouring cup (1), the first horizontal sprue (2), and the four branch channels (3) are respectively connected. The horizontal gating system (8) and the water inlet plate (9) are integrally formed by casting. The water inlet plate (9) includes a lower water inlet plate (4) and an upper water inlet plate (7). The lower water inlet plate (4) and the upper water inlet plate (7) include the lower water inlet cross-sectional area (401) and the lower water inlet plate size (402), and the upper water inlet cross-sectional area (701) and the upper water inlet plate size (702). The upper casting (5) and the lower casting (6) are respectively placed inside the upper water inlet plate (7) and the lower water inlet plate (4).

[0013] The specific workflow is as follows: molten iron flows through the pouring cup, sprue, gating 1, gating 2, 4 branch lines, two separate inlet plates, upper and lower mold inlets, and upper and lower mold castings. In the optimized process, the design of the front end of the 4 branch lines is the same as the original process. Molten iron enters through the pouring cup and sprue, first flows through gating 1, then through gating 2, filling both gating lines (i.e., the molten iron floats to the surface), and then enters the 4 branch lines. The branch lines are also filled first before the molten iron enters the two separate inlet plates. The purpose of this method is to collect some impurities, sand, slag, oxides, etc. in the molten iron at the front end of the gating system to ensure the cleanliness of the molten iron. Under the premise of consistent front-end conditions, after the molten iron fills the four branch channels, it rises to the inlet plate. The molten iron in the inlet plate flows back through the inlet blocks of the upper and lower molds, and then simultaneously enters the upper and lower mold castings. However, at this point, the size ratio of the upper mold inlet plate to the lower mold inlet plate needs to be 2:1. This is the most important point in designing this process. In addition to meeting this condition, the cross-sectional area ratio of the upper mold inlet to the lower mold inlet also needs to be 2:1. By controlling the amount of molten iron entering the lower mold, the upper mold casting can also be filled with molten iron. For this improved solution, the ratio of the above two positions is key to achieving simultaneous filling of the upper and lower molds with molten iron. The above description is only a preferred embodiment of this utility model and is not intended to limit this utility model. For those skilled in the art, this utility model can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A novel brake disc casting structure for improving product quality, characterized in that, It includes a pouring cup (1), a first horizontal runner (2), four branch runners (3), a lower mold water inlet plate (4), an upper mold casting (5), a lower mold casting (6), an upper mold water inlet plate (7), a second horizontal runner (8), and a water inlet plate (9). The pouring cup (1) is placed above the first horizontal runner (2), and two sets of water inlets plate (9) are installed on each side of the four branch runners (3).

2. The novel brake disc casting structure for improving product quality according to claim 1, characterized in that, The pouring cup (1), the first horizontal sprue (2), the four branch channels (3), the second horizontal sprue (8), and the water inlet plate (9) are integrally formed by casting.

3. The novel brake disc casting structure for improving product quality according to claim 1, characterized in that, The water inlet plate (9) includes a lower water inlet plate (4) and an upper water inlet plate (7).

4. The novel brake disc casting structure for improving product quality according to claim 1, characterized in that, The upper casting (5) and the lower casting (6) are respectively placed inside the upper water inlet plate (7) and the lower water inlet plate (4).

5. A novel brake disc casting structure for improving product quality according to claim 3, characterized in that, The lower water inlet plate (4) and the upper water inlet plate (7) include the lower water inlet cross-sectional area (401), the lower water inlet plate size (402), the upper water inlet cross-sectional area (701), and the upper water inlet plate size (702).

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