Optimization of Synchronizer of a Typical 5-Speed Manual Shift Synchromesh Transmission Using Statistics - Based Simulation Techniques

This paper presents a new methodology evolved for the optimized design of synchronizers of automotive synchromesh transmission using statistical simulation techniques. The design methodology involves developing a transfer function relating the design parameters of synchronizer with that of the performance requirements. An analytical model of the synchronizer is developed, validated and used for optimization. The synchronizer design parameters such as synchro cone angle, mean radius and blocker/cone friction co-efficient are studied for continuous variation between two set levels based on design constraints. The performance requirements i.e., shift quality, synchronization efficiency and synchronizer life are predicted based on gear shift force, clash ratio and specific power dissipation & Hoop stresses respectively. The optimal value for these design parameters within the defined design space is also presented.