Supersprox
Supersprox next gen sprockets for KTM/Husqvarna
Factory racing teams are always looking for an edge. working with many top teams and with development as new materials and manufacturing techniques become available and in response to the feedback they get from the race team managers they work with. In the past three years, engine performance has affected the durability of the commonly used technologies for the production of engine drive sprockets. Companies are responding with a different approach.
Looking closely at all the products in the racing line, because in the near future historically suitable technologies will start to age out. Bikes are getting too powerful and racing partners are pushing to have their suppliers think outside the box. With assistance from technical institutes, approache this problem scientifically and analyse how weak points in the parts produced using established manufacturing techniques develop under the varying conditions and loads they are exposed to. The results are surprising. It would not be possible to solve the issues with existing metallurgy. A solution proposed on the bases of a radical change in process.
‘closed die, hot forging’
Supersprox claims that this new process increases the sprocket tooth and core strength by more than 20%. Compared to billet machined parts, the process offers significant advantages. In a part made from billet, flow lines develop in the microstructure. The properties become anisotropic – that is to say that the physical properties of the material have a different value when loaded equally in different directions, meaning parts can fail under dynamic stress.
“During forging, impurities align themselves along these flow lines. The microstructure flow lines in a forged part will be much finer than a billet microstructure and therefore stronger and more durable. Special details are being added into the forging to provide the highest strength at the teeth and spline area – something that can’t be done with CNC-machining a billet”.
‘microstructure flow lines’
A unique ultra-low carbon steel (purchased in Japan) should be used for the sprockets, helping to provide a very stable condition in the base metal. Although the sprocket doesn’t have holes drilled, it is actually lighter than the OEM sprocket because of the surface indentations. The aluminium core in this sprocket is a technical feature, allowing the sprocket to retain a critical thickness in an area where steel is not required.
