Optimization of synchronizer cone angle with regard to manufacturing tolerances of cone roundness and cone angle

The effects of manufacturing tolerances on the maximum focal temperature has been investigated by transient thermomechanical simulations. Both relative cone angle and cone out-of-roundness for molybdenum and carbon fibre reinforced polymer synchronizers were evaluated. It was shown that cone out-of-roundness significantly increases the focal contact temperature for that specific cone but has little impact on the opposing cone. Two populations of measured synchronizers were evaluated, and it was shown that the maximum focal surface temperature can be decreased in almost all tolerance cases by introducing a relative angle between the cones.