Synchronizer Ring Axial Groove Manufacturing via Vibratory Grinding
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Solution Overview
Problem
Existing synchronizer ring manufacturing methods do not effectively enhance the performance and durability of conical friction surfaces, particularly in multiple-cone systems where high friction forces are required, and often result in burrs and uneven surfaces that increase seizing tendencies.
Innovation Solution
A method involving chipless machining to create axial grooves on conical friction surfaces during forming, followed by vibratory grinding and nitriding to produce a smooth, hardened surface with rounded edges and microreservoirs for improved tribological properties, reducing seizing and increasing overload capacity and sliding speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining methods are used to create grooves on the friction surface, then the manufacturing process is simple, but burrs and uneven surfaces are produced that increase seizing tendencies
Solution Approach 1:
The patent applies vibratory grinding to the friction surface after groove formation. The vibratory motion of the grinding tool prevents burr formation and produces a burr-free, smooth surface that reduces seizing tendency while maintaining manufacturing efficiency
Solution Approach 2:
The grooves are formed in the friction surface before the final vibratory grinding step. This preliminary groove formation allows subsequent vibratory grinding to effectively smooth the entire surface including groove edges, eliminating burrs that would cause seizing
2Ease of manufacture
If the friction surface is left unhardened, then the manufacturing process is simpler and more cost-effective, but the overload capacity and durability are reduced
Solution Approach 1:
The patent applies nitriding treatment to harden the friction surface after groove formation and vibratory grinding. This parameter change in material hardness increases overload capacity and durability while maintaining the burr-free surface quality achieved by vibratory grinding
3Productivity
If the friction surface is not ground, then manufacturing is faster and cheaper, but the surface roughness increases seizing tendency and reduces sliding speed capability
Solution Approach 1:
Vibratory grinding is applied as a relatively quick finishing process that produces a smooth, burr-free surface capable of withstanding high sliding speeds. The process is more efficient than conventional grinding while achieving the necessary surface quality for high-performance operation
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
The method results in a synchronizer ring with enhanced overload capacity, increased sliding speed, reduced seizing tendency, and simplified, cost-effective manufacturing, with improved tribological properties and a smooth, burr-free surface.
Implementation Method 1
Vibratory grinding of at least of the friction surface
Implementation Method 2
subsequent hardening of the friction surface, in particular by nitriding
Data Source
AI summary
A synchronizer ring (10) for synchronized manual transmissions is manufactured by forming or reshaping a flat material of metal, wherein a conical friction surface (20) is produced, into which axial grooves (24) are incorporated by chipless machining, wherein a tool is axially shifted relative to the friction surface (20) to produce the final friction surface (20). At least the friction surface (20) is vibration-ground and subsequently hardened.