Synchronizer Ring Roof Ridge Width Reduction via Rear Recess Embossing
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Solution Overview
Problem
Conventional synchronizer rings face limitations in reducing sheet thickness due to required tooth height, resulting in a non-ideal roof ridge width that affects functionality and weight, with existing methods being costly and restrictive.
Innovation Solution
A method involving embossing a recess on the rear side of locking teeth opposite the roof ridge during the forging process, allowing material flow and improved mold filling, enabling the use of thinner sheet metal without compromising functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If sheet thickness is reduced to decrease weight, then weight is reduced, but the required tooth height cannot be achieved
Solution Approach 1:
A recess is embossed on the rear side of the locking tooth before the final forming process. This preliminary action creates space that allows material to flow towards the roof ridge during forming, enabling adequate tooth height to be achieved even with thinner sheet metal.
Solution Approach 2:
The solution introduces a new dimensional feature (the recess) on the rear side of the tooth, which is opposite to the roof ridge area. This additional dimensionality allows material redistribution without increasing overall sheet thickness, thereby maintaining tooth height geometry while using thinner material.
2Ease of manufacture
If conventional forming processes are used, then manufacturing is simple, but the roof ridge width cannot be minimized
Solution Approach 1:
The recess is embossed on the rear side of the locking tooth during the forming process, which preliminarily prepares the material distribution. This causes material to flow towards the roof ridge area, minimizing the roof ridge width while keeping the forming process relatively simple and robust.
3Weight of moving object
If sheet thickness is reduced, then weight is reduced, but mold filling in the roof ridge area becomes insufficient
Solution Approach 1:
By embossing the recess on the rear side of the locking tooth before final forming, the material is pre-positioned to flow towards the roof ridge area. This preliminary action ensures adequate mold filling in the critical roof ridge region even when using thinner sheet metal with less material available.
Solution Approach 2:
The recess introduces a new dimensional feature on the rear side of the tooth, creating space for material redistribution. This allows the material to flow axially towards the roof ridge, improving mold filling quality without increasing sheet thickness.
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 enhances mold filling in the roof ridge area, achieving a minimal roof ridge width, reducing weight, and increasing the robustness of the forming process, allowing for synchronizer rings made from sheet metal as thin as 1.5 mm to 3.0 mm, while maintaining required tooth geometry.
Implementation Method 1
embossing the desired shape... allows material to flow in the direction of the tooth roof consisting of the roof flanks and the roof ridge
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The invention relates to a method for manufacturing a synchronizing ring (1) for a synchronizing device, in which radially outwardly or radially inwardly extending locking teeth (2) are formed by a forging process, each having a flank section (7) and two inclined roof flanks (8, 9) terminating in a common roof ridge (10), wherein a recess (12, 13, 14, 15, 16, 17) is formed on the rear side (11) of a locking tooth (2) opposite the roof ridge (10). The invention also relates to a synchronizing ring (1) manufactured according to the described method.