Abstract
Synchronizers are widely used in gear boxes of car and truck transmissions. Optimizing costs and improving the efficiency of gear boxes require knowledge about the relative load limits of single and multi-cone synchronizers with carbon friction linings and their corresponding deterioration mechanisms. Load limits for single and multi-cone synchronizers with carbon friction lining used in cars were determined experimentally using the component test rig SSP-180 and compared against each other. Different load stages were run in life cycle tests and the influences of pressure, sliding velocity, friction work, frictional power and oil temperature were investigated. The synchronizers’ failure mode is described and the novel specific value μmin,grad is introduced that is able to quantify the deterioration of different synchronizer systems. During life cycle tests at the same specific load level, the single cone synchronizers, contrary to expectations, displayed greater damage compared to the multi-cone synchronizers. Calculations of the friction surface temperature in thermo-mechanical simulations, in combination with experiments on the test rig, show that the maximum temperature during the engagement has a significant influence on deterioration and endurance life of synchronizers with carbon friction lining.
Highlights
Synchronizers are widely used in gear boxes of car and truck transmissions
This study aims to determine load limits and introduces an evaluation method to compare the performance of different synchronizer systems
Load limits for single and multi-cone synchronizers with carbon friction lining used in cars were determined experimentally using the component test rig SSP-180
Summary
Synchronizers are widely used in gear boxes of car and truck transmissions. These machine elements synchronize the rotational speed of the output shaft and the gear wheel to be engaged to ensure smooth gear changing. A cone clutch with up to three friction surfaces is used to accelerate or decelerate input shaft and gear wheel, which have different rotational speeds. Torque generated between the axial plane surfaces of the inner ring and the gear wheel is much smaller than that between the friction surfaces. It contributes approximately 5% to the overall torque of the whole synchronizer [4]. A triple cone synchronizer has an additional conical friction surface on the inner ring which is in contact with a cone on the gear wheel. Abdel Halim et al [6] demonstrates the advantages of multicone synchronizers compared to single cone synchronizers, like greater torque capacity theoretically, and on the test rig
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