engineering report

(32)

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

HOERBIGER & CO, Schongau

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

Performance and cost optimization

of friction systems for single and
multiple surface synchronizers

Summary
The synchronizer is one of the most important
components of any manual gearbox. Increasing
performance, reducing shift force and optimizing the
between the gears costs are the primary objectives
for the new generation of synchronizer systems.
Improvement in capacity of the brass system and the
introduction of formed sinter cones are detailed in this
article. With the help of these new developments,
existing synchronizer designs can be economically
re-engineered into more efficient designs.

1. Introduction
The majority of European high volume production
manual gearboxes presently use brass synchronizer
rings (Borg Warner system) . In addition a single cone
outer synchronizer is also used, offering a slightly
higher load capacity for the same diameter. To fully
optimize the available space, it is necessary to modify
the complete system. The options available are to
move to multiple cone synchronizers, increase the
diameter, or to change to an alternative friction material
(Molybdenum, Paper, Sinter). In recent years, the use
of the HOERBIGER sinter friction lining, either as a
welded foil, or as deep drawn single or dual cone rings,
has resulted in many extremely successful solutions.

2. Current Situation
In practice there are 2 basic systems, and developed
derivatives of them, in use - Borg Warner and Outer
Synchronizer systems. Figure 1 shows the schematic
layout of these systems and the relative market share.

SINGLE CONE

Borg
Warner

Fig 1:

MULTI CONE

Outer
Cone

Dual
Cone

Triple
Cone

Current Synchro Systems

Manufacturing of the most important components

utilizes sintering, sinter forging and precision forging
processes. The majority of mass production manual
gearboxes, use a special brass alloy material (SoMs)
on the basis of its advantageous cost / performance
ratio. The brass alloy must function as a base material
and a friction material, therefore a compromise
between material strength and friction performance is
needed.
The oil grooves, necessary for function and cooling,
require an expensive machining process. This results
in a relatively low friction surface area, leading to high
specific loads on the remaining surface.
In the past, the only way to upgrade the load capacity
of the brass was to coat the friction surface with
molybdenum. This has only a small advantage, due to
the tendency for the increased loads and pressure to
exceed the mechanical capabilities of the brass
material, resulting in deformation of the rings. Alternative higher strength materials can be used, but these
require the expensive bonding/welding of additional
friction material. The following table shows the
available options and combinations.

Base Material

Friction Lining

Opposing Surface

Sinter Metal (PM)

Formed Steel

Molybdenum
- thin / thick layer
Organic Friction lining
Dispersion Sinter

Steel / PM
- case hardened,
ground and honed

Forged Part

2.1 Comparison of the most important friction

linings for modern synchronizers
In addition to brass and molybdenum, sinter and
organic linings are also found in synchronizers. The
sinter lining was to date exclusively found in high
energy shift positions. Organic friction linings play only
a minor role in European synchronizer applications.
Organic Linings
approx. 5%
Brass
approx. 55%

HOERBIGER & CO, Schongau

2.1.1 Wear behavior of the synchronizer friction

surface
External tests, carried out by various neutral research
institutions [2], and field applications [1,3] have shown
that under typical application conditions, sinter and
moly linings show good to very good wear properties,
while under the high surface pressure, resulting from
the geometry of the synchronizer, brass and organic
friction linings show a relatively high degree of wear.

1,0

Brass

Axial wear [mm]

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

Sinter
approx. 15%

Paper
0,5
Molybdenum

Molybdenum
approx. 25%
0,2

Fig 2:

Market Share of todays friction materials in

current synchronizers

0,1

- Dispersion Sinter Friction Linings

During the sintering process, friction linings,
consisting of brass powder, frictional stabilizers and
non metallic elements (C, Si, etc.), are bonded to a
steel carrier. This carrier is then either welded inside
a blocker ring or formed into a single or dual cone
(HOERBIGER Patent).
- Molybdenum
Applied using a flame spraying process, on a profiled
blocker ring, ground (thick layer) and / or calibrated.
- Organic Lining
Fibrous material with an organic matrix, (Cotton,
Phenolic Resin) with inclusions of frictional and
structural stabilizers. Organic linings are normally
bonded to the carrier ring using adhesive.
The four friction materials, brass, sinter, molybdenum
and organic, show considerable differences in their
behavior.

0,5

1,0

Specific energy [J/mm2]

Fig 3:
- Special Brass Alloy (SoMs)
The friction surface is profiled during the forging
process.

Sinter

Wear behavior of synchronizer friction linings

2.1.2 Wear on the mating cones

With mating cones hardened to 60 HRC, paper, brass
and sinter friction linings show no wear on the mating
cones, while molybdenum linings tend to show fretting
on the mating cones.

2.1.3 Maximum permissible load

A series of publications [1,2,5,6 ] documents that sinter
friction linings show an extremely high load limit (Fig 4),
not achievable with brass, organic or molybdenum
linings.
The high thermal conductivity and porosity of the sinter
linings, in combination with the high thermal capacity of
the oil stored within its pores, ensures a low
temperature of the friction surface. This is of benefit not
only to the friction material, but also the thermal stress
of the oil
Thin molybdenum coatings show almost equivalent
performance to sintered friction linings, under low
differential speeds. At higher surface speeds (10 m/s)
traces of overheating (frictional martensite) are
evident, developing into fretting on the cone surface.

HOERBIGER & CO, Schongau

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

Organic linings are basically a risk under high surface

pressures in synchronizers. Even when operated
below the thermal capacity limit, unacceptable
reduction in the wear reserve can occur.
Brass is unsuitable for permanent energy loads greater
than 0.1 J / mm2, due to wear.

Step
1
2
3
4
5
6

rpm

V (m/s)

450
820
1230
1590
1800
1900

Energy (J)

2.3
4.2
6.4
8.2
9.3
9.8

Specific Energy

(J/mm2)
0.51
0.92
1.39
1.79
2.03
2.14

1237
2254
3381
4370
4950
5223

Table 1: Abuse-Test
Maximum permissible friction
loading (J/mm2)

4,0

to 4,0

3,0
2,5
2,0

2.1.5 Comparison
An attribute performance comparison of the different
linings is given in Table 2.

(Fretting)
1,5

1,0

1,2

Brass

Fig 4:

This Abuse Test led to the introduction of sinter linings

in a mass production passenger car application.

Mo

Paper

HS

Maximum permissible friction loading (J / mm2)

Attribute
Wear (friction surface)
Wear (mating cone)
Load Capacity (J/mm2)
Dynamic friction
Frictional stability
Abuse performance
Oil compatibility

Sinter Paper

++
o
+++
+
+
+++
++

Mo-Thin Layer

-o
++
++
++
++
++

+
++
+
o
o
+

2.1.4 Overload capacity (Abuse conditions)

Abuse tests are particularly common in the USA. Table
1 shows the test designed to simulate the behavior of
the particularly sporty driver, who does not shift
correctly. The assumption behind this test is that many
of these drivers do not fully depress the clutch pedal
while changing gear (grinding the gears) or force the
synchro ring to the mating cone, without controlling the
clutch (gear lever in neutral; a habit from using an
automatic transmission).

Bewertungsbasis: Synchronring aus Sondermessing

In both cases this means that the synchronizer must

absorb considerably more energy.

All variations of the brass single cone designs, have

the disadvantage that the increase of the synchronizer
capacity, by the addition of a friction lining, means a
substantial increase in cost.

Table 2: Comparative assessment of alternative

friction materials

high

PERMISSIBLE LOADING

Standard

50 lbs = 281 N
7.5:1
2109 N
2.5 s
100 mm

Fig 5:

Forged Ring+HOERBIGER
Sintered Bronze

PM+HOERBIGER
Sintered Bronze

PM+Molybdenum/Paper

Brass+Molybdenum

Steel +Paper

Brass

low

Handball Load:
Lever Ratio:
Axial Force:
Compression period:
Synchro Ring Diameter:

Brass (SoMs)
deterioration
-- substantial
- minor
o none

COST

This abuse test, with its high differential speeds, led to

the functional problems with molybdenum and organic
linings. The moly linings showed fretting while the
matrix of the organic linings suffered a massive thermal
overload (carbonization).

Basis
improvement
+++ substantial
++ clear
+
minor

Comparison of cost and permissible loading of

currently available components on the market

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

3. HOERBIGER New Developments

HOERBIGER has developed a cost effective
manufacturing technology that makes it possible to
use a sinter lining inside a brass or steel single cone
synchronizer ring. In addition HOERBIGER has also
introduced a modular system that allows upgrading
from a single to a multi surface synchronizer, at
minimum cost.

3.1 Components

3.1.1 Brass ring with formed

HOERBIGER sinter (HS) foil

HOERBIGER & CO, Schongau

3.1.1.3 Quality Assurance

The mechanical connection between the sinter foil and
the carrier blocker ring has been shown in several tests,
to have a safety factor that is 10 times the real
application load.

Max.
Friction Torque

Achieved
Torque

Max.
Axial Force

Achieved
Force

20 Nm

> 250 Nm

800 N

> 7000 N

Table 3: Mechanical test of the bonding

(ring size 60 mm)

3.1.1.4 Advantages compared to conventional

systems

Fig 6:

Brass ring with formed HS Foil

3.1.1.1 Background of the project

The development goal of this project, was to combine
the advantages of two well known and widely approved
materials into a new product.

1 : 1 replacement of existing solution

Short development times for the customer
Use of a proven friction lining
Cost reduction when compared to conventional
upgrades of a brass system
Improvement in shift comfort
Smoother shifts
Noise reduction
Improved durability
Cost savings in the mating cones
(elimination of honing)

3.1.2 Deep drawn steel ring with sinter lining

- Low cost of brass as a base core material

- High load capacity friction lining

3.1.1.2 Manufacturing
In a further development of the existing HOERBIGER
manufacturing technology for double cone rings, a flat
steel ring with friction lining is formed in a fully automatic
process. This is then mechanically fixed, in a single
step, inside a brass ring. The forming of the foil around a
chamfer at the front and rear of the brass ring ensures
the axial location, while the pressing of the foil into axial
grooves prevents rotation.

Fig 7:

Deep drawn single cone ring

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

3.1.2.1 Background of the project

Due to the material structure of the brass core, high
loads can lead to typical failure modes of tooth wear or
fracture of the ring. The higher heat expansion of brass
also means that the axial gap needs to be higher.
The alternative materials are all high cost options
(Powder Metal parts, steel forged parts) .

The higher strength of the steel allows significant

reduction of the thickness, offering a greater friction
diameter. The necessary design changes are to modify
the mating cone diameter, the center diameter of the
hub and a minor change to the stone design. The
structure of the friction material is such that the forming
process does not influence it, meaning
Homogeneous porosity of the friction lining
Precise definition of oil grooves
(for good cold performance)

The logical development goal was to improve the

durability of the core material and to combine it with the
advantages of a sinter lining.

Tensile Strength Elastictiy Limit

E-Modul
Heat Expension
[N/mm2]
[N/mm2]
x 103 [N/mm2]
x 10-6 1/K
CuZn40Al2
SoMs
Sint D 30
C 35

590

270

103

21

510
650

370
400

130
210

9
11

Extensive rig and transmission tests, have shown the

function and load capacity performance of the formed
single cone to at least match existing systems.

3.1.2.3 Advantages compared to conventional

systems
Weight reduction of approx. 45 %
Improved material
Increased friction radius
Cost effectiveness
Elimination of heat treatment

Table 4: Comparison of Materials for synchro rings

3.1.2.2 Production
A sintered sheet is formed using an automatic multi
stage process, ideally suited for mass production, into a
single cone ring with sintered friction lining, gear teeth
and indexing lugs. The cold working of the teeth
normally permits elimination of a heat treatment
operation
It is possible to form several types of indexing during
this process.

3.1.3 Comparison of costs

The new developments of brass ring and HS foil and
deep drawn steel ring with HS foil, open new
possibilities to use proven materials in a cost effective
manner, ideally suited to mass production applications.
Fig 9 shows the cost comparison of both conventional
and HOERBIGER solutions in terms suitability for
various application conditions.
HOERBIGER product

Fig 9:

Drawn Steel Ring+HOERBIGER

Sintered Bronze

Brass+HOERBIGER
Sintered Bronze

Forged Ring+HOERBIGER
Sintered Bronze

PM+HOERBIGER
Sintered Bronze

PM+Molybdenum/Paper

Different indexing lugs

Brass+Molybdenum

Fig 8:

Steel +Paper

Brass

low

passenger car

COST

high

truck

Standard

Comparison of standard solutions and

HOERBIGER solution

The graph shows that both products offer very

attractive production prices.

PERMISSIBLE LOADING

HOERBIGER & CO, Schongau

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

HOERBIGER & CO, Schongau

3.2 Synchronizer systems

3.2.1 Modular construction for synchronizer

systems
The ever increasing need in modern gearboxes for
improved shift comfort and higher energy capacity, has
led to the redesign of the single cone system. To date
this was only achievable by using a larger diameter or
multiple surfaces.
Unlike other known single cone systems,
HOERBIGER equips the inner cone with the friction
lining. The cone is connected to the clutch ring by drive
lugs.

Sliding sleeve
Gear wheel
Synchronizer ring
Single cone friction ring
Clutch body

Synchronizer body

System HOERBIGER

System BW

Fig10: Comparison HOERBIGER / BW System

This system, in which only the outer surface of the inner

ring is used, is similar in construction to the standard
dual cone system. The design allows a capacity
increase to the double or triple cone style, simply by
adding more friction surfaces. (Fig 11).
The modular system in Fig 11, shows a deep drawn
steel ring replacing the conventional PM blocker ring.

Fig 11: Single / Double / Triple Cone System

HOERBIGER & CO, Schongau

3.2.2 Cost Optimized Friction Pairings

The use of brass or moly gives rise to high requirements
of geometry and surface finish on the mating cones.
These costly operations can be eliminated by the use of
HOERBIGER sinter linings.

Axial Wear
(% v baselinge) (% v baselinge)

Mating Surface
Material

St. 1.2379 60 HRC

PM 1 carbon nitrided
PM 1 plasma nitrided
PM 2 gas nitrided
PM 3 final sintered
PM 4 standard
PM 5 standard
PM 5 case hardened
PM 5 HCO traitement

Performance and cost optimization of friction systems

for single and multiple surface synchronizers

61.6
77.7
100.0
90.3
73.6
75.0
75.0
89.8
94.4

uniform size of synchro ring on all gears

easily upgradeable to a multiple surface system
use of approved friction lining on all gears
no additional friction lining for highly loaded gears
manufacturing of components with no machining
operations
wide range of applications
proven costs savings of up to 22 %

Ratio
Static
Dynamic

42.3
26.3
100.0
52.3
69.0
95.8
98.6
55.2
48.6

1.05
1.44
1.07
1.045
1.55
1.345
1.455
1.215
1.225

4. Conclusion
As a result of continuous process development and
the use of innovative production techniques, it is now
possible to utilize the sinter friction linings in cost
effective solutions for high volume applications of
components and systems.

Table 5: HS 450 in conjunction with various surfaces

The flexible structures of the new lining compositions
allow the use of rougher or lower hardness surfaces on
the mating cones. Table 5 shows the wear behavior
characteristics of this new lining. The conclusion being
that even unhardened surfaces can be used.

3.3 Cost Comparison

The following comparison of a conventional design with
an optimized dual cone system shows how the use of
the above components leads to cost effectiveness

Synchro-system
double cone brass

Advantages compared to a conventional system

Synchro-system
double cone steel

The modular system is a further step towards the

standardizing of all gears within a gearbox and its
associated benefit of increased component volume,
leading to more competitive prices.

Bibliography:
[1]

[2]

[3]

[4]

Material
powder metal

sintered part

Cost
Index [%]
13

steel

case hardened
machined grooves

28
18

brass
steel

Type

Part

Cost
Index [%]
10

Type

Material

calibrated

Sint D39

shifter sleeve
blocker ring

20
14

calibrated
deep drawn

Sint D39
steel

hub

hardened

19

clutch body

14

stamped steel

steel

steel

hardened/
ground

14

12

deep drawn

steel / friction
material

brass

machined grooves

intermediate ring
friction ring
inner ring

deep drawn

steel

springs balls

100

78

In addition to the available 22% cost reduction, the

optimized system also offers performance advantages
for the individual components.

[5]

[6]

Thelen E., P. Wunderlich, J. Foth und I. Schmidt:

Reibungs- und Verschleiverhalten moderner Reibschichten fr
Synchronisierungen.
Praxisforum, 1990
Pflaum H.:
Das Reibungsverhalten lgeschmierter Kegelreibkupplungen in
Synchroneinrichtungen von Kfz-Schaltgetrieben.
TU Mnchen, Dissertation, 1989
Brgel, E., K. Christian und P. Wunderlich:
Entwicklung einer Mehrfach-Synchronisierung fr Nfz-Getriebe.
VDI Tagung Getriebe in Fahrzeugen heute und morgen. April 1991
Lanzerath, G. und H. Patzer:
Neuartiger Synchronring mit organischem Belag.
Antriebstechnik 25/1986
HOERBIGER Information:
HS - Sinter-Reibbelge in Synchronisierungen.
August 1989
Vojacek, H. und H. Pflaum:
Verwendung von Streusinter-Reibbelgen in Reibkupplungen.
Deutsches Patent DE 317813 C1

STEEL DISCS SPRING PLATES BRAKE DISCS

DISCS WITH SINTER- AND MOLYBDENUM FRICTION LININGS
DISCS WITH ORGANIC FRICTION LININGS
SYNCHRONISER FRICTION RINGS- AND SYSTEMS
FLEX PLATES PROCESS TECHNOLOGY

HOERBIGER ANTRIEBSTECHNIK GMBH Im Forchet 5 D-86956 Schongau Phone (08861) 210-0 Fax (08861) 210-309 Headquarter
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