Research on the punch-extrusion composite forming process of synchronizer ring

Currently, precision forging serves as the mainstream process for manufacturing synchronizer rings. While it ensures dimensional accuracy of components, it still faces challenges such as insufficient tooth profile filling, short tool life, and low production efficiency. To solve the above problems, this study applied Sheet-Bulk Metal Forming (SBMF) technology to the manufacturing of steel synchronizer rings and designed a punch-extrusion composite forming process flow. The tooth profile parameters of the core tooth extrusion process were optimized by means of Deform-3D software and the backpropagation (BP) neural network prediction model. The simulation results demonstrate that the optimized tooth extrusion process enables complete filling of the tooth profile cavity, with the maximum distance between the tooth tip and the die reduced by 14.81%, and the die wear magnitude decreased by 24.73%. Production trials demonstrate that, in comparison with the conventional precision forging process, the new process realizes a fourfold increase in die lifespan and an eightfold rise in production efficiency, with material utilization efficiency also substantially improved. This punch-extrusion composite forming process has certain guiding significance for the actual production of this steel synchronizer ring.