Development of an SSP-180 Synchronizer Durability Test

Synchronizers are designed to provide smooth, efficient and safe transfer of torque between mechanical gears. Friction level, durability, and consistency of the fluid / friction lining system are crucial to ensuring crisp gear engagements without clashing and noise, vibration and/or harshness (NVH) for the life of the transmission. Excellent wear control of gears, synchronizer ring and cone surfaces is also critical to protecting the life of moving mechanical parts. The SSP-180 synchronizer rig measures friction durability and wear up to 100,000 engagements, using a variety of fluids and friction materials. Methodology for the development of a synchronizer durability procedure using the SSP-180 rig is presented for qualifying fluids for dry dual clutch (DCT) and manual transmission (MT) applications for General Motors. It will be shown that the new DEXRON® SSP-180 Synchronizer Durability Test in Appendix C of the GMW 16612 fluid specification [1] satisfies four key conditions for new mechanical test methods: discrimination, repeatability, effective failure mode analysis, and reasonable test duration.