Synchro Design Calculator

Calculate synchronizer cone torque and shift effort for manual transmission gear engagement analysis.

Input Parameters

Results

--
Required Sync Torque
N-m
--
Axial Force
N
--
Shift Lever Force
N
--
Energy Absorbed
J
Note: Modern synchros use molybdenum-coated brass or carbon-lined cones with mu=0.08-0.12. Double or triple cone designs reduce shift effort. SAE paper 2006-01-0360 covers synchro design.

Reference

delta_omega = RPM_diff × 2pi / 60 Sync Torque = J × delta_omega / t_sync Axial Force = T_sync × sin(alpha) / (mu × R_cone) mu ≈ 0.10 (molybdenum-coated brass) Shift Force = Axial_force / Lever_ratio Energy = 0.5 × J × delta_omega²