Increasing Robustness and Reliability of a Race Car Engine. Patrick Bandeira
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1 Increasing Robustness and Reliability of a Race Car Engine Patrick Bandeira
2 About us
3 LOCATIONS»Banbury»Milton Keynes
4 NEW HEADQUARTERS»120,000 sq ft»next to M40, Banbury
5 Not only motorsport ON THE ROAD IN THE AIR ON THE WATER
6 PRODRIVE»Founded in 1984»~500 staff Motorsport Advanced Technology Bespoke collections Aston Martin Racing Systems Engineering MINI WRC Electronics & Control VW Rally Carbon composites
7 PRODRIVE Motorsport Advanced Technology Bespoke collections Aston Martin Racing Systems Engineering MINI WRC Electronics & Control VW Rally Carbon composites
8 MOTORSPORT»Aston Martin Racing»VW Rallying»Vehicle design & engineering
9 IN MOTORSPORT»One of the largest independent, full capability motorsport organisations in the world»aston Martin Racing - Vantage GTE - Vantage GT3 - Vantage GT4»VW Golf SCRC»MINI - WRC - RRC - RX
10 MOTORSPORT ACHIEVEMENTS»1150 events: rallies races»274 wins rallies races»2317 car starts»6 World Rally Championship titles»4 Le Mans 24 Hours titles»3 FIA WEC titles»le Mans Series champions»4 British Touring Car Championships»BAR F1 Team 2nd in F1 World Championship under Prodrive management
11 PRODRIVE Motorsport Advanced Technology Bespoke collections Aston Martin Racing Systems Engineering MINI WRC Electronics & Control VW Rally Carbon composites
12 ADVANCED TECHNOLOGY»Combining our motorsport culture with robust engineering processes and quality procedures to produce solutions that enhance our clients' products and solve their technical challenges»sectors - automotive - defence - aerospace - marine - power generation»today s clients include - Jaguar Land Rover - McLaren - Ford - Ben Ainslie Racing - Airbus Defence & Space
13 ADVANCED TECHNOLOGY»Innovation & creative solutions over 20 years»applying motorsport technologies to road car design»providing turn-key design & supply solutions»consortium approach to new IP R&D»Over 100 qualified engineers
14 SYSTEMS ENGINEERING»Efficient Powertrains - Electric & flywheel hybrids - DC-DC converters - Automated manual transmissions»chassis - Base chassis design - Active driveline control ATD»Interior systems - Bespoke mechatronic systems - Vehicle & module production»active aero - Bespoke electric and hydraulic actuation - Module production and delivery
15 CARBON COMPOSITES»One of the largest UK plants for design & manufacture of carbon composite parts & assemblies»40,000 sq ft facility»180 staff»sectors - automotive - aerospace - marine - motorsport»today's clients - McLaren Automotive - Airbus Defence & Space - Bentley - Jaguar - Sikorsky
16 PRODRIVE Motorsport Advanced Technology Bespoke collections Aston Martin Racing Systems Engineering MINI WRC Electronics & Control VW Rally Carbon composites
17 BESPOKE COLLECTIONS»Bespoke branded clothing & accessory collections»full in-house service: product design, manufacture, distribution & fulfilment»sectors - Motorsport - Sport - Automotive»Clients - VW Motorsport - Hyundai - Pirelli - Jaguar Land Rover - Aston Martin - Sahara Force India
18 PRODRIVE DNA our culture our values professionalism & performance can do : our attitude creative : how we think rigorous : our strive for perfection relentless : our commitment integrity : our pride our essence neverstop >> dreaming innovating creating performing exceeding competing winning
19 Use of Altair Software
20 Possibilities with ALTAIR»Altair Hyperworks»Altair Partner Alliance - Token based license system suits Prodrive s business model
21 ALTAIR HYPERWORKS»FEA - Fast Turnaround - Scripting Capabilities - Optimisation
22 ALTAIR HYPERWORKS»Pre-processing for Full-Vehicle CFD - Scripting Capabilities - Geometry Defeaturing - Shrink Wrap Meshing - Quick Turnaround when building models
23 ACUSOLVE»Special Projects: Acusolve»Ongoing Development»Benchmarking and Development»Evaluation of the flow in the Water Jacket in an Aston Martin Racing 4.5L V8
24 ACUSOLVE»Special Projects: Acusolve»Geometry Preparation and Meshing»Preliminary Flow, checking for dead zones and flow recirculation
25 ACUSOLVE»Special Projects: Acusolve»Bleed Holes
26 ACUSOLVE»Bleed Holes»Post Processing Template
27 ACUSOLVE»Bench Testing: Use of temperature probes inside a development cylinder head
28 ACUSOLVE»Bench Testing: Use of temperature probes inside a development cylinder head
29 Temp delta to Outlet Temp (degrees C) STD GASKET TEST1 DRILLED GASKET TEST1 STD GASKET TEST2 DRILLED GASKET TEST2 ACUSOLVE»Bench Testing: Use of temperature probes inside a development cylinder head CYLINDER HEAD LOCATION
30 First Iteration Head Preparation 1080 Engine Build 3200 Additional Parts 2500 Instrumentation 400 Dyno Time 2000 Total 9180 Further Iterations Head Preparation 1080 Engine Build 1600 Dyno Time 2000 Total 4680 ACUSOLVE»Comparison: -Time -Costs
31 FURTHER DEVELOPMENT»ACUSOLVE - Coupled Fluid-Thermal Analysis - Other Special Projects (i.e Fuel Filling system, Radiator Flow)»HYPERMATH - Incorporate into our current workflow, substituting third party software»hypermorph - Streamline the workflow in both FEA and CFD modelling so geometries don t have to go back to designers to be altered.
32 Questions?
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