Synchronizer Ring Grooving via Axial Tool Displacement
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Solution Overview
Problem
Current methods for producing synchronizer rings are costly and lack efficiency in producing high-quality rings with high transmissible frictional forces, often requiring additional coating and machining steps.
Innovation Solution
A method involving forming a flat metal material into a conical friction surface with axially extending grooves produced by axial displacement of a tool, followed by hardening, without subsequent coating or cutting, to create a synchronizer ring with integral ratchet teeth, reducing manufacturing costs and enhancing frictional forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If subsequent coating and machining steps are used to produce synchronizer rings, then the quality and transmissible frictional forces are improved, but the manufacturing costs and process complexity increase
Solution Approach 1:
The patent combines multiple manufacturing operations (forming, grooving, and hardening) into a single integrated process sequence. The grooves are formed during the deep-drawing process itself, and the hardening is performed immediately afterward, eliminating the need for separate coating and machining steps that would otherwise be required to achieve the desired friction surface properties
Solution Approach 2:
The grooves are formed in advance during the deep-drawing process, before the hardening step. This preliminary formation of the groove structure allows the subsequent hardening to directly create the finished friction surface with the required properties, eliminating the need for post-hardening coating or machining operations
2Force
If additional coating steps are applied to the friction surface, then the transmissible frictional forces are enhanced, but the manufacturing costs and production time increase
Solution Approach 1:
The friction surface serves its own function by forming grooves during the deep-drawing process itself. The material deformation during forming creates the groove structure that, after hardening, provides the necessary friction characteristics without requiring any additional coating materials or separate friction-enhancing treatments
3Manufacturing precision
If grooves are produced by rolling or embossing before forming, then the friction surface quality is improved, but the manufacturing process complexity and costs increase
Solution Approach 1:
The patent merges the groove formation operation with the deep-drawing forming process. A single deep-drawing tool performs both the forming of the conical friction surface and the creation of the grooves in one continuous operation, eliminating the need for separate rolling or embossing steps that would be required to achieve similar groove structures
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 method results in a synchronizer ring with reduced assembly costs and increased transmissible frictional forces, achieved through a simplified and cost-effective production process that integrates grooves and ratchet teeth into a single part, eliminating the need for additional machining or coating.
Implementation Method 1
forming a flat metal material so that at least one conical friction surface is produced
Implementation Method 2
subsequent hardening of the synchronizer ring
Data Source
Figure 1~4
Figure 5~7
AI summary
The invention relates to a synchronizing ring (1) for synchronized manual transmissions, which is produced by shaping a flat metal material. The conical friction surface (6) is provided with grooves (8) which are produced exclusively by axially displacing a tool in relation to the friction surface (6). Said friction surface (6) remains uncoated. In the region of the friction surface (6), the counter conical ring, as well as the friction surface, does not have a subsequently applied friction layer.