This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Unloaded Synchronizer Wear in Manual Transmission Gearbox
ISSN: 0148-7191, e-ISSN: 2688-3627
Published September 25, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Event: International Conference on Advances in Design, Materials, Manufacturing and Surface Engineering for Mobility
Synchronizers are the most critical parts of a manual transmission. There are classical calculations available for the synchronizer design and studies are available for the normal functioning of synchronizer rings which describes how the synchronizer behaves in the event of gear shifting. The objective of this study is to describe the synchronizer behavior when synchronizers are not functional, i.e., in other gear engaged condition and the rings are free. This study describes the failure mechanism of the unused synchronizer rings which are moving freely in the packaging space. The findings of this synchronizer design cannot be limited only for synchronizer performance and standard durability calculations. To ensure proper function of synchronizer rings and to achieve the required life the external parameters like clearances, lubrication, clutch design for dampening torsional vibration from the engine are to be considered. From the tests, it's observed that the high-speed difference and the vibrations cause the burning of the synchronizer ring and the wear of the threads. This burning increase exponentially with the increase in the testing time. This technical paper covers the failure mechanism and the methodology to avoid unloaded synchronizer wear. The study presented in this paper describes the synchronizer behavior when synchronizers are not functional either gear is engaged, or other gear is engaged in transmission.
CitationK, B., Goel, S., MENON, P., and K, J., "Unloaded Synchronizer Wear in Manual Transmission Gearbox," SAE Technical Paper 2020-28-0334, 2020, https://doi.org/10.4271/2020-28-0334.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
|[Unnamed Dataset 3]|
|[Unnamed Dataset 4]|
|[Unnamed Dataset 5]|
- Socin, R., and Walters, L. , “Manual Transmission Synchronizers,” SAE Technical Paper 680008, 1968, https://doi.org/10.4271/680008.
- Seaman, R., Johnson, C., and Hamilton, R. , “Component Inertial Effects on Transmission Design,” SAE Technical Paper 841686, 1984, https://doi.org/10.4271/841686.
- Shen, Y., Liu, Z., and Rinderknecht, S. , “Modelling of Power Losses of Transmission Synchronizers in Neutral Position,” SAE Technical Paper 2018-01-1228, 2018, https://doi.org/10.4271/2018-01-1228.
- Barathiraja, K., Devaradjane, G., Paul, J., Rakesh, S. et al. , “Analysis of Automotive Transmission GEARBOX Synchronizer Wear due to Torsional Vibration and the Parameters Influencing Wear Reduction,” Engineering Failure Analysis 105:427-443, 2019.