For Formula 1 racing, unremitting innovation is its source of power. The team's tireless work is to achieve peak performance during the game, which is the core spirit of the Renault F1 team. The key to the team's ability to achieve its goals is the team's dedication to vehicle performance improvement and the capabilities of its technology partners.
Nick Chester, technical director of the Renault F1 team, said: "Through one game after another, through the rigorous testing of R&D and simulation experiments, the vehicle parts made of complex composite materials and aerospace alloys let us see At the end of the season, we hope that the car can be rotated more than once per second, which is a very demanding requirement for our technology partners. But we can't accept partners who can't bring us vehicle performance improvement. ""
The Renault team in Enstone, England, has been using 3D Systems technology in its core operations since 1998. As an early adopter of 3D printing prototypes, the use of 3D printing by the team is also based on the development of 3D printing technology. Early use was mainly made on functional and fitting design verification and fixtures and fixtures for precision assembly.
As the collaboration deepens, 3D Systems' application engineers help Renault's teams use 3D printing technology more deeply. The team is capable of conducting wind tunnel tests and has a positive impact on the cooperation between the two parties and the innovation of automotive components through 3D printing investment casting.
Technical Director Chester said: "The support that Renault has received from 3D Systems is also changing with the advancement of its technology. If we look back, you can see that as the material performance improves, the team has already printed 3D. The application has expanded into more engineering fields. The number of auto parts per year through 3D printing has increased year by year, and the team has benefited a lot from design versatility, reduced production time and cost reduction."
Image: 3D printed precision casting molds help produce large, complex metal parts faster, source 3D Systems
The 3D Systems equipment recently used by the Renault team includes two SLA printers and three selective laser-sintered SLS printers. Materials include: fabrication of fixtures & fixtures, liquid flow devices, Accura materials for investment casting prototypes; DuraForm PA materials for wind tunnel test components; and DuraForm GF materials for automotive components such as electrical boxes and cooling channels.
Every year, the Renault team designed and built a new car to respond to changes in the rules of the game, which is also their constant innovation, designed to improve car performance. For example, changes in the rules of the car will bring many challenges. The 2017 season update includes bigger and heavier tires, wider front wings, lower and wider rear wings and higher diffusers, which means that the 2016 season The parts used cannot be used in the 2017 season.
Image: Metal Printing Helps Innovative Exploration of Automotive Parts, Source 3D Systems
Once the season begins, the pressure will continue to escalate: sometimes only a short week can be used to make engineering changes to parts. From the dedicated track to the street race, each game brings engineers with a huge variety of structures and climates in the type of track.
Quick verification design
From the outset, 3D printed prototypes have proven to be very useful in making compact interior parts for racing cars. The Renault team quickly saw the potential of 3D printing in the field of fitting and functional testing as they noticed that 3D Systems equipment can make extremely complex parts. Realizing this, they began to use more 3D printing technology and gradually extended from rapid prototyping to wind tunnel model manufacturing.
Warner mentioned: "In wind tunnel tests, aerodynamics is an empirical science. We choose design directions by designing and comparing new concepts. The more design concepts we compare and evaluate, the more we will win. Big."
Development of dynamics driven by wind tunnel testing
The aerodynamics department of the Renault team has grown significantly in recent years, with 120 aerodynamicists, wind tunnel technicians and model builders. Warner said that this is also largely due to the use of 3D printing technology from 3D Systems. He introduced complex internal runner technology into the design of wind tunnel test models, an important impact of 3D Systems technology and an opportunity to obtain more pressure readings.
Warner said: "The vehicle model in the wind tunnel test is in a complex pressure sensing network. Before the SLA technology is used, the metal and carbon fiber components need to be positioned by drilling. Now we can make complex flows inside. The entity of the Tao has completely improved the ability to place more sensors. This is like an aerodynamicist's dream come true."
Warner estimates that the single wind tunnel test requires 600 3D printed parts per week, completed by a team of five engineers from Advanced Digital Manufacturing (ADM).
Manufacturing speed and accuracy of automotive parts
In terms of productivity and efficiency, 3D printing has significantly improved the ability of the Renault team to cope with different game environments. Using SLA and SLS technology, complex fixtures and fixtures, liquid flow devices and automotive parts can be produced in hours, eliminating weeks. This makes 3D printing technology an ideal choice for Formula 1 racing.
In addition to testing a large number of automotive components in wind tunnel tests, the Renault team also made some automotive components directly. Renault's chief operating officer, Rob White, said: "3D Systems' technology provides us with a new and efficient process that allows us to reduce production time and cost, adding significant value to the team. On the other hand, we are excited about the fact that the same part can be iterated several times in the wind tunnel test. On the other hand, we also note that more sintered parts are used in actual vehicle manufacturing every year."
3D printing helps the fleet make parts that are lighter and faster and more fuel efficient, while at the same time providing accurate flow testing, as well as improved engine performance and reduced wear. Once the design is complete, the sample data and selected materials are produced by the ADM department. With SLA and SLS technology, the efficiency of manufacturing complex automotive parts is much better than ever.
SLA prototypes are becoming more common in applications such as gearboxes and suspension components, so the design of fleet engineers is even more limited. The SLA process is highly accurate, which not only saves a lot of time when producing prototypes, but also saves a lot of time during post-processing.
(Editor)
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