A Method to Optimize Brass Type Single Synchronizer Ring for Manual Gearbox
Khollam .S.C1, Mhaske M S2, Belkar S B3
1Khollam .S.C, Dept, Research Scholar, Mechanical, Pravara Rural Engineering, College, Loni.
2Prof Mhaske M S,  Asst professor, Dept,  Mechanical, Pravara Rural Engineering, College, Loni.
3Dr. Belkar S B,  HOD Dept, Mechanical, Pravara Rural Engineering, College, Loni.
Manuscript received on January 25, 2014. | Revised Manuscript received on February 16, 2014. | Manuscript published on February 28, 2014. | PP: 93-98  | Volume-3, Issue-3, February 2014. | Retrieval Number:  C2588023314/2013©BEIESP

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Abstract: Global automotive industry is growing rapidly in recent years. Increased torque range with deeper transmission ratio as well as overall vehicle refinements in modern trucks places higher demands on transmission and its components. Changing market requirement and driver comfort is also a new challenge in commercial market. With this overall effects design and development of transmission and its components plays a major role for performance, comfort and economically driven market. Synchronizer is one of the critical components which need to look upon. Synchronizer plays a vital role for gear shifting performance in manual gearbox without any shifting assistance. Synchronizers primary function is to reduce the rpm difference between two gears before gear shifting subject to time and more comfort. Increasing demand for performance, enhance life, less shift effort, less synchronization time, optimum size of Synchro pack and low cost has become an interesting area for engineer for improvement. More over existing synchronizer can be economically re-engineered into more efficient designs with the help of new mathematical tools and techniques. A mathematical optimization model can be developed to establish optimum cone parameter. A model of relationship can built between cone angle and sleeve champers angle, synchronizer size, coefficient of friction, cone torque and index torque. In this study a model was built in Matlab optimization toolbox pattern-search solver to find global minimum value of Cone angle which satisfy set of given and known design constrains. This Model can be used to select first cut synchro parameter with moderate accuracy. These Values can be then finer tune by customized and specialized software’s. It is not easy to study the entire gear-changing process from clutch till wheels, dynamical behavior of manual gearbox is too complicated to simulate, owing to the large number of elements involved in it. This study considers only major parameter involved in synchronization. Also generous experience and data is required to accurately select parameter with desired Shift feel and comfort.
Keywords: Synchronizer, Matlab, Blocker ring, optimization Gearbox.