Sliding Sleeve Production via Cold Pilgering and Segmentation
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Solution Overview
Problem
The production of sliding sleeves for synchronous manual transmission assemblies is costly due to individual machining methods, which do not offer significant quality improvements.
Innovation Solution
A method involving a tubular blank with an internal toothing arrangement is used to produce multiple sliding sleeves through plastic deformation, specifically cold pilgering, followed by subdividing and further processing to create segments with varying tooth shapes and outer contours, reducing material usage and increasing stability via cold work hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual machining method is used to produce sliding sleeve, then manufacturing precision can be maintained, but production cost increases and productivity decreases
Solution Approach 1:
The internal toothing arrangement is segmented into multiple identical tooth patterns that are simultaneously formed on a single blank through plastic deformation. The blank is then divided into multiple sliding sleeves, each inheriting the toothing arrangement. This segmentation allows parallel production of multiple components with consistent quality.
Solution Approach 2:
The internal toothing arrangement is pre-formed on the blank through plastic deformation before the blank is divided into individual sliding sleeves. This preliminary action ensures that the complex toothing geometry is established once for multiple components, avoiding repeated machining operations and ensuring uniform quality across all produced sliding sleeves.
2Manufacturing precision
If individual machining method is used to produce sliding sleeve, then quality can be maintained, but production cost increases
Solution Approach 1:
Multiple sliding sleeves are combined into a single production process by forming the internal toothing arrangement on a common blank that contains multiple segments. The plastic deformation process simultaneously creates the toothing arrangement for all future sliding sleeves, merging what would otherwise be separate machining operations into one cost-effective process.
Solution Approach 2:
The internal toothing arrangement is pre-formed on the blank through plastic deformation before the blank is divided into individual sliding sleeves. This preliminary action ensures that the complex toothing geometry is established once for multiple components, avoiding repeated machining operations and ensuring uniform quality across all produced sliding sleeves.
3Loss of substance
If plastic deformation method is used to produce internal toothing arrangement, then material usage is reduced and stability is increased, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process transitions from material removal (machining) to material transformation (plastic deformation). By changing the fundamental parameter of how the toothing arrangement is created—from subtractive to deformative manufacturing—the process achieves better material utilization and inherent work hardening, despite the complexity of the deformation tooling required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs while maintaining quality by enabling the production of multiple sliding sleeves with complex internal toothing arrangements in a single operation, enhancing material stability and wear resistance.
Implementation Method 1
the internal toothing arrangement is produced by means of plastic deformation of the blank
Implementation Method 2
the stability of the sliding sleeve is increased by reason of the cold work hardening of the material during deformation
Data Source
AI summary
A sliding sleeve for a synchronous manual transmission assembly is produced by the following steps:a tubular blank is provided in which an internal toothing arrangement is present, andthe blank which is provided with the internal toothing arrangement is further processed to form a plurality of sliding sleeves.