Synchronizing Ring Manufacturing via Powder Metallurgy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing synchronizing rings for variable-ratio gear transmissions require high labor and machining efforts to achieve the necessary precision and true running properties, particularly in terms of roundness and carrying capacity.
Innovation Solution
The method involves compressing and sintering a ring body from powder, axially compressing it in a die to achieve radial displacement, gluing a carbon nonwoven friction lining bonded with duroplastic resin to the conical inner circumference, and compacting and curing the lining in a mold under pressure and heat, eliminating the need for further machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conical inner circumference of the synchronizing ring is machined before applying the friction lining, then the precision and true running properties are improved, but the manufacturing outlay and labor effort increase
Solution Approach 1:
The conical inner circumference is prepared in advance during the sintering process itself, where the sintering material is compacted and radially displaced against the shaping outer cone of the die. This preliminary shaping action eliminates the need for subsequent machining operations while maintaining the required precision for friction lining application.
Solution Approach 2:
The traditional mechanical machining process is replaced by a powder metallurgy forming process. The sintering process with axial compression and radial displacement against a shaped die cone substitutes for conventional CNC machining or lathe operations, reducing both labor and equipment requirements while achieving the necessary geometric precision.
2Ease of manufacture
If the friction lining is glued onto the conical inner circumference without mold compaction, then the manufacturing process is simpler, but the precision and tolerance deviations are not compensated
Solution Approach 1:
The friction lining undergoes compaction under controlled pressure and temperature conditions in a mold. This changes the physical parameters of the lining material, causing it to densify and conform precisely to the conical inner circumference. The heat and pressure parameters compensate for existing tolerance deviations in the ring body, achieving the required precision without additional machining.
3Productivity
If the ring body is not axially compressed in the die, then the manufacturing process is faster, but the true running properties and roundness are insufficient
Solution Approach 1:
The axial compression of the sintered ring body in the die is performed as a preliminary shaping step before friction lining application. This compression action, combined with radial displacement against the shaped die cone, establishes the correct geometry and true running properties in advance, eliminating the need for subsequent corrective machining operations.
Solution Approach 2:
The sintered ring body is formed from powder metallurgy materials that exhibit specific compaction and sintering characteristics. The combination of axial compression and radial displacement during sintering creates a composite structure with improved density and geometric accuracy, achieving true running properties that would require excessive machining if formed by conventional methods.
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 precision and true running properties while reducing manufacturing outlay, ensuring low tolerances and adequate strength for the synchronizing ring without additional machining, thereby meeting high precision and carrying capacity requirements.
Implementation Method 1
compressing the ring body from a sintering powder and sintering the compressed ring body
Implementation Method 2
the sintering material is not only compacted, but rather also radially displaced, so that the sintering material is compressed against the outer cone of the die
Implementation Method 3
compacting and curing the friction lining in a mold under pressure
Implementation Method 4
curing the friction lining in a mold under pressure while supplying heat
Data Source
AI summary
To manufacture a synchronizing ring of a synchronizing device for a variable-ratio gear transmission, this synchronizing ring having a ring body having locking teeth on an outer circumference and a friction lining made of a carbon nonwoven material bonded to a duroplastic resin on the conical inner circumference, the ring body is compressed from a sintering powder and sintered before the sintered ring body is axially compressed in a die at least in the region of the conical inner circumference. The friction lining is then glued onto the conical inner circumference of the ring body and secured in a mold under pressure while supplying heat.