Project Brief

The synchronizing crown (or synchronizer ring) is one of the most complex components in a gearbox. It plays a crucial role in matching the rotational speeds of gears before engagement, ensuring smooth and efficient gear shifting. Its complexity comes from the precise machining, material properties, and surface treatments required to provide durability, wear resistance, and optimal friction characteristics. Additionally, tight dimensional tolerances and precise synchronization mechanisms make it a highly intricate part of the transmission system.

category

Automation engineering,Heat Treatment,Machining

client

Automotive

start date

2020

end date

2021

Annual Volume

1.2 Million

innovative process

The challenge

The primary challenge in manufacturing synchronizer cones lies in maintaining strict dimensional tolerances and ensuring uniform hardness throughout the component. Each step in the process, from machining to heat treatment, must be precisely controlled to avoid defects such as warping, surface irregularities, and uneven material properties. Additionally, achieving cost efficiency while maintaining high product quality and process repeatability remains a significant challenge. The integration of advanced machining technologies and quality control measures is essential to overcome these obstacles.

project goals

  • Ensure precision manufacturing of synchronizer cones with tight dimensional tolerances.
  • Achieve uniform hardness and wear resistance through optimized heat treatment.
  • Minimize production defects and improve overall manufacturing efficiency.
  • Implement quality control measures to meet industry and customer specifications.
  • Optimize cost-effective manufacturing without compromising product reliability.
  • Automatically measure 100% of the inner diameter after grinding and 100% of radial run-out to ensure the proper function of the part.
  • The synchronizer cone manufacturing process involves turning, hobbing, tooth pointing, heat treatment, and inner grinding to achieve high precision and durability.
  • The primary challenge is maintaining strict dimensional accuracy and uniform hardness while optimizing cost and efficiency.
  • The project aims to enhance quality, minimize defects, and improve process efficiency, ensuring a reliable and industry-compliant final product.

the result

By implementing an optimized manufacturing process, the project ensures the production of high-quality synchronizer cones with consistent dimensional accuracy and durability. The improved process minimizes defects, reduces material waste, and enhances productivity, leading to cost-effective and efficient production. Additionally, the implementation of stringent quality control measures guarantees compliance with industry standards and enhances the overall reliability of the product.

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