SYNCHRONIZER HUB FOR VEHICLES AND METHOD FOR MANUFACTURING THE SAME

Abstract

A synchronizer hub for vehicles and a method for manufacturing the same forms an inner spline and an outer spline of a transmission synchronizer hub for vehicles by using different materials.

The synchronizer hub may be manufactured by filling inner powders for forming the inner spline, molding the inner spline, filling outer powders for forming the outer spline, molding the outer spline, separating the double molded object obtained by integrally forming the inner spline and the outer spline from a mold, and performing sintering, post-processing, and high-frequency heating processes.

Claims

1-6. (canceled)

7. A method for manufacturing a synchronizer hub for vehicles, comprising: filling inner powders for forming an inner spline in a first space formed between a mold main body, a first mold positioned on an upper side, and a second mold positioned on a lower side; press-molding the inner powders in the second mold by using a first press to form the inner spline; moving the first mold to the lower side, and filling outer powders for forming an outer spline in a second space formed between the mold main body, the first mold, and the molded inner spline; rotating an upper part of a press by approximately 180 degrees to change a position of the first press to a second press, and press-molding the outer powders by using the second press to integrally form the outer spline and the inner spline; raising the first mold and the second mold to the upper side to separate a double molded object obtained by integrally forming the inner spline and the outer spline from a mold; and performing a sintering process, a post-processing process, and a high-frequency heating process on the double molded object.

8. The method for manufacturing the synchronizer hub for vehicles of claim 7, wherein in the step of press-molding the inner powders, the first press is applied to the inner powders at a room temperature under a pressure of 6.5 to 7.5 g/cm3.

9. The method for manufacturing the synchronizer hub for vehicles of claim 7, wherein in the step of press-molding the outer powders, the second press is applied to the outer powders under a pressure of 6.6 to 7.6 g/cm3, which is relatively greater than a pressing pressure of the inner powders.

10. The method for manufacturing the synchronizer hub for vehicles of claim 7, wherein the sintering process is performed in a sintering furnace at a temperature of about 1000 to 1300 C. under a gas mixture atmosphere of hydrogen and nitrogen for about 20 minutes to one hour.

11. The method for manufacturing the synchronizer hub for vehicles of claim 7, further comprising: cooling the double molded object by controlling a cooling velocity to be 0.2 to 0.60 C/sec between the sintering process and the post-processing process.

12. The method for manufacturing a synchronizer hub for vehicles of claim 7, wherein the heating process is performed by performing a high-frequency heating process on a boss by using a cylindrical coil.

13-18. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The above and other features of the present invention will now be described in detail with reference to certain exemplary embodiments thereof illustrated the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:

[0025] FIG. 1 is an exploded perspective view of a part to which a synchronizer hub for vehicles according to the present invention is applied;

[0026] FIG. 2 is a cross-sectional view of a double molded object of the synchronizer hub according to the present invention;

[0027] FIGS. 3(a) to 3(d) illustrate schematic cross-sectional views for describing a process of molding and manufacturing the synchronizer hub according to the present invention; and

[0028] FIGS. 4(a) and 4(b) are microscope photographs for checking frictional wear amounts of an outer spline (SMF9060M) of a synchronizer hub manufactured in Example according to the present invention before and after a heating process, and FIGS. 4(c) and 4(d) are microscope photographs for checking frictional wear amounts of an inner spline (FL5208) of the synchronizer hub before and after the heating process.

[0029] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.

[0030] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0031] Hereinafter reference will now be made in detail to various embodiments of the present invention, examples of which are illustrated in the accompanying drawings and described below. While the invention will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention to those exemplary embodiments. On the contrary, the invention is intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.

[0032] It is understood that the term vehicle or vehicular or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example both gasoline-powered and electric-powered vehicles.

[0033] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0034] Hereinafter, the present invention will be described in detail in connection with one implementation embodiment.

[0035] The present invention relates to a synchronizer hub for vehicles which is formed as a double molded object obtained by forming an inner spline and an outer spline of a transmission synchronizer hub for vehicles by using different materials. FIG. 2 is a cross-sectional view of a double molded object of a synchronizer hub according to the present invention. In FIG. 2, reference numeral 100 denotes an inner spline, and reference numeral 200 denotes an outer spline.

[0036] According to the present invention, the inner spline may be made of 0.6 to 0.8 weight % of carbon, 0.15 to 0.30 weight % of molybdenum, 1.3 to 1.7 weight % of chrome, and a remainder of iron. Further, the outer spline may be made of 0.7 to 0.9 weight % of carbon, 0.45 to 0.60 weight % of molybdenum, 0.60 to 3.0 weight % of nickel, 1.3 to 1.7 weight % of copper, and a remainder of iron.

[0037] Accordingly, the synchronizer hub according to the present invention is formed as a double molded object obtained by forming the inner spline and the outer spline by using different materials from each other, and may be preferably formed as an integrated double molded object in which the inner spline is made of 0.6 to 0.8 weight % of carbon, 0.15 to 0.30 weight % of molybdenum, 1.3 to 1.7 weight % of chrome, and a remainder of iron, and the outer spline may be made of 0.7 to 0.9 weight % of carbon, 0.45 to 0.60 weight % of molybdenum, 0.60 to 3.0 weight % of nickel, 1.3 to 1.7 weight % of copper, and a remainder of iron.

[0038] The inner spline according to the present invention is formed through molding by using inner powders having the above-described composition, and the carbon component is a main element that is used to secure a mechanical property such as strength and facilitates a heating process. When the carbon component is too small, mechanical strength may be deteriorated, and when the carbon component is too large, impact strength may be degraded by brittleness. The molybdenum and chrome are components that are added to improve a mechanical property such as strength. When the molybdenum and chrome are too small, mechanical strength may be deteriorated, and when the molybdenum and chrome are too large, machinability may be degraded, which is undesirable.

[0039] As a material of the inner spline according to the present invention, a material that is subjected to a heating process and has a high material property after the heating process may be used. Preferably, a pre-alloy in which other metal powders are melted in iron may be used.

[0040] According to the present invention, the outer spline is formed through molding by using outer powders having the aforementioned composition, and the carbon component is a main element that is used to secure a mechanical property such as strength and facilitates a heating process. When the carbon component is too small, mechanical strength may be degraded, and when the carbon component is too large, impact strength may be degraded by brittleness. The molybdenum is a component that is added to improve a mechanical property such as strength. When the molybdenum is too small, mechanical strength is deteriorated, and when the molybdenum is too large, machinability may be degraded. Thus, this is not preferable. The nickel is a component that is used to secure tensile strength and elongation. When the nickel is too small, strength and elongation such as impact strength is degraded by brittleness, and when the nickel is too large, a property such as mechanical strength is degraded. The copper is used to secure a mechanical strength such as strength. When the copper is too small, mechanical strength is degraded, and when the copper is too large, the mechanical strength is degraded due to infiltration.

[0041] As a material of the outer spline according to the present invention, a material that is not subjected to a heating process and has a high material property before the heating process may be used, and a diffusion alloy in which other metal powders are diffused in iron may be preferably used.

[0042] The synchronizer hub formed as the double molded object according to the present invention may be preferably formed by sintering and high-frequency heating processes.

[0043] The synchronizer hub formed as the double molded object according to the present invention describes that a wear resistance of the inner spline is improved as compared to that of a conventional synchronizer hub by about 800%, and cost is further reduced as compared to that of the conventional one by about 20%.

[0044] Meanwhile, a process of manufacturing the synchronizer hub according to the present invention will be described in detail in connection with one implementation example.

[0045] The synchronizer hub according to the present invention may be manufactured through a step of filling the inner powders for forming the inner spline, a step of molding the inner spline, a step of filling the outer powders for forming the outer spline, a step of molding the outer spline, a process of separating the double molded object obtained by integrally forming the inner spline and the outer spline from a mold, and a step of performing sintering, post-processing and high-frequency heating processes. FIGS. 3(a) to 3(d) illustrate schematic cross-sectional views for describing a process of molding and manufacturing the synchronizer hub according to the present invention. FIG. 3(a) illustrates a step of filling the inner powders, FIG. 3(b) illustrates a step of molding the inner spline by a first press, FIG. 3(c) illustrates a step of filling the outer powders, and FIG. 3(d) illustrates a step of molding the outer spline by a second press.

[0046] According to the present invention, the inner powders used for the inner spline and the outer powders used for the outer spline are respectively prepared. The inner and outer powders are prepared to have the aforementioned compositions.

[0047] According to the present invention, inner powders 101 for forming an inner spline 100 are filled in a first space formed between a mold main body 20, a first mold 21 positioned at an upper side, and a second mold 21 positioned at a lower side. In this process, the inner powders 101 having the aforementioned composition are filled using a filling shoe.

[0048] Subsequently, the inner spline is press-molded using a first press 31 in the second mold 22. In particular, the inner spline 100 is molded by pressing the filled inner powders 101 at room temperature under a pressure of 6.5 to 7.5 g/cm.sup.3.

[0049] Thereafter, the first mold 21 is moved to the lower side, and outer powders 201 for forming the outer spline 200 are filled in a second space formed between the mold main body 20, the first mold 21, and the molded inner spline 100.

[0050] Subsequently, a press main body 30 is rotated by approximately 180 degrees to change a position of the first press 31 to a position of the second press 32, and then the outer spline 200 is molded using the second press 32. At this time, the outer powders are pressed at a room temperature under a press of 6.6 to 7.6 g/cm3, which is relatively greater than the pressing pressure of the inner powders. By performing this step, the double molded object obtained by integrally forming the inner spline and the outer spline is manufactured. By doing this, it is possible to manufacture the synchronizer hub for vehicles formed as the double molded object as a product having preferable mechanical properties.

[0051] Thereafter, the first mold and the second mold are raised to the upper side to separate the double molded object obtained by integrally forming the outer spline and the inner spline from a mold.

[0052] The sintering, post-processing, and high-frequency heating processes are performed on the separated double molded object, and these processes may be performed by the same methods as those used in a typical process of manufacturing the synchronizer hub.

[0053] According to the present invention, in the process of sintering the double molded object, the double molded object is sintered in a sintering furnace of, for example, about 1000 to 1300 C. under a gas mixture atmosphere of hydrogen and nitrogen for about 20 minutes to one hour. In this process, preferably, a material for forming the inner spline includes molybdenum and chrome that are easily oxidized, and, thus, the sintering process is performed under a hydrogen atmosphere.

[0054] After the sintering process, a step of cooling the molded object is typically performed to perform the post-processing process, and the cooling step may be performed by a typical method. However, it is possible to secure a mechanical property through structure control in the cooling step. Accordingly, when a cooling velocity is too fast, since volume fractions of bainite and martensite are increased, brittleness may be increased, and when the cooling velocity is too slow, since a volume fraction of pearlite is increased, strength may be decreased. In particular, after the cooling, a volume fraction of pearlite in the inner spline is preferably 80 to 89%, and a volume fraction of bainite in the inner spline is preferably 10 to 20%. A volume fraction of martensite in the outer spline is preferably 50 to 60%, and a volume fraction of pearlite in the outer spline is preferably 50 to 40%. To achieve this, the cooling velocity is preferably controlled to be 0.2 to 0.6 C./sec.

[0055] The post-processing process is precisely performed on the cooled double molded object to obtain a synchronizer hub having an appropriate shape and standard, so that a shape of the synchronizer hub is finished. The post-processing process is performed by a typical method.

[0056] A product is finished by performing the heating process on the post-processed synchronizer hub. At this time, in the heating process, for example, a high-frequency heating process is preferably performed on the boss by using a cylindrical coil. By doing this, it is possible to perform the high-frequency heating process on only the boss without hardening the entire synchronizer hub.

[0057] The synchronizer hub according to the present invention manufactured through the steps is preferably attached to a manual transmission to be applied as a product having excellent quality.

[0058] Accordingly, the present invention includes the manual transmission including the synchronizer hub according to the present invention.

[0059] According to the synchronizer hub for vehicles according to the present invention manufactured through the above-stated steps, it is possible to reduce cost, and since the synchronizer hub for vehicles has improved mechanical properties such as strength as compared to a conventional synchronizer hub and its manufacturing process is relatively simple, it is possible to economically manufacture the synchronizer hub for vehicles.

[0060] As mentioned above, since the synchronizer hub for vehicles according to the present invention has a double molded object structure and can be made of an optimized material, it is possible to improve mechanical properties and to provide a design with a reduced weight.

[0061] Hereinafter, the present invention will be described in detail in connection with examples, but is not limited to the examples.

EXAMPLES

[0062] The following examples illustrate the invention and are not intended to limit the same.

[0063] Powder materials for manufacturing the synchronizer hube are prepared as follows. Diffusion alloy powders of SMF9060M (Fe-4.0Ni-1.5Cu-0.5Mo weight %) (4,941 won/kg) are prepared as the inner powders used for the inner spline. Further, pre-alloy powders of FL5208 (Fe-1.5Cr-0.2Mo weight %) are prepared as outer powders (2,850 won/kg).

[0064] By using the manufacturing process illustrated in FIGS. 3(a) to 3(d), the inner powders for forming the inner spline is filled in the first space formed between the mold main body, the first mold positioned on the upper side, and the second mold positioned on the lower side by using the filling shoe, and the inner spline is press-molded in the second mold by using the first press. At this time, the inner spline is molded by pressing the inner powders at a room temperature under a pressure of 6.9 g/cm.sup.3.

[0065] Subsequently, the first mold is moved to the lower side, and the outer powders are injected into the second space formed between the mold main body, the first mold, and the molded inner spline. Thereafter, the press main body is rotated by 180 degrees, and the outer spline is molded using the second press. At this time, the outer spline is molded by pressing the outer powders at a room temperature under a pressure of 7.0 g/cm.sup.3. The entire density is set to 7.0 g/cm.sup.3 to manufacture the double molded object obtained by integrally forming the inner spline and the outer spline.

[0066] The first mold and the second mold are raised to the upper side to separate the double molded object from the mold, and the separated double molded object is sintered in the sintering furnace of 1140 C. under the gas mixture atmosphere of hydrogen and nitrogen in the proportion 10:90 for 30 minutes. Thereafter, the cooling is performed by controlling a cooling velocity to be 0.4 C./sec, and the double molded object in which a volume fraction of pearlite in the inner spline is 85%, a volume fraction of bainite in the inner spline is 15%, a volume fraction of martensite in the outer spline is 55%, and a volume fraction of pearlite in the outer spline is 45% is obtained.

[0067] The post-processing process is precisely performed on the cooled double molded object to obtain the shape of the synchronizer hub, and the high-frequency heating process is performed on the boss by using the cylindrical coil to manufacture the synchronizer hub for vehicles.

Test Examples

Test Example 1

[0068] In order to evaluate a material property of the synchronizer hub manufactured in the above-described example, a mechanical property is measured, and the measured result is represented in Table 1. The measured result of the material property of the inner spline is different from the measured result of the material property of the outer spline, and there is a great difference between of wear amounts of the inner and outer splines after the heating process.

TABLE-US-00001 TABLE 1 Frictional wear Frictional wear Yield Tensile Impact amount before amount after Hardness strength strength value heating process heating process Category (HV10) (Mpa) (Mpa) (J) (m.sup.3) (m.sup.3) Outer spline 246 460 657 27.7 6881 6577 (SMF9060M) Inner spline 250 623 712 26.0 9080 869 (FL5208)

[0069] Metal microstructure of the product is observed, and microstructure photographs of the inner and outer splines before and after the heating process are represented as the observed result in FIG. 4.

[0070] Referring to (a) and (b) of FIG. 4, since a Ni element in the outer spline (SMF9060M) forms a Ni-rich-Austenite region to prevent a solid solution of C, the content of C is relatively increased in a matrix, so that a martensite structure is formed even before the heating process to reduce a frictional wear amount. However, since the Ni-rich-Austenite region remains after the heating process, the volume fraction of martensite is not increased, and, thus, a frictional wear amount approximates to the frictional wear amount before the heating process.

[0071] In contrast, referring to (c) and (d) of FIG. 4, both pearlite and bainite structures of the inner spline (FL5208) are changed to martensite through the heating process, and, thus, frictional wear mounts are reduced.

Test Example 2

[0072] In order to evaluate a property of a part (a reference product of a super large size, rear-wheel drive, 6-speed, and first and second gear) of the synchronizer hub manufactured in the above-described example, a mechanical property is measured, and a result obtained by comparing the measured mechanical property with that of Conventional Example is represented in Table 2. Here, the conventional example is a synchronizer hub including only the outer spline (SMF9060M).

TABLE-US-00002 TABLE 2 Hardness of boss Hardness of inner spline of outer Density (high-frequency heating spline Category (g/cm.sup.3) process unit, HRC) (HV10) Conventional 7.0 40-41 252 (248 nal Example Ex Example 7.0 47-48 263 (261-275)

[0073] Further, fracture and torsion (fatigue) tests for the part are performed under the following conditions.

[0074] [Fracture Test]

[0075] It is checked whether or not fracture is caused in 450 Nm (equipment maximum limit, required torque1.2), and the condition is a strain rate of 0.05 deg/sec.

[0076] [Torsion Test]

[0077] Condition 1: torque322 to 3220 Nm (required torque1.5), torque ratio (max/min)10, evaluation speed10 Hz, cycle200,000 times

[0078] Condition 2: torque n speed10 Hz, cycle200,000 t1.85), torque ratio (max/min)), torque ratio (speed10 Hz, cycle200,000 times

[0079] As the test results, the fracture test result is represented in Table 3.

TABLE-US-00003 TABLE 3 Category Slope (Nm/Degree) Test result Conventional 5441.6 OK (no damage) Example Example 5587.6 OK (no damage)

[0080] Furthermore, the torsion test result is represented in Table 4.

TABLE-US-00004 TABLE 4 Test torque Target Test Category Test mode (Nm) Cycles result Conventional Condition 1 Required 322 to 200,000 OK Example torque 3220 (no damage) 1.5 Condition 2 Required 400 to 500,000 OK torque 4000 (no damage) 1.85 Example Condition 1 Required 322 to 200,000 OK torque 3220 (no damage) 1.5 Condition 2 Required 400 to 500,000 OK torque 4000 (no damage) 1.85

[0081] As the test results, it can be seen that even though the synchronizer hub is formed as the double molded object, the synchronizer hub has an excellent mechanical property, the synchronizer hub is very suitable to be applied to an actual product. Particularly, it can be seen that the product (Example) according to the present invention has remarkably an excellent mechanical property in comparison to the existing product (Conventional Example).

[0082] Since the synchronizer hub for vehicles according to the present invention is formed as the double molded object, it is possible to improve mechanical properties, to reduce the cost, and to decrease weight.

[0083] The invention has been described in detail with reference to preferred embodiments thereof. However, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.