Bugatti Bolide has titanium 3D printed parts »3dpbm

With the help of the technical concept of Bugatti Bolide, the French luxury car manufacturer now provides the answer to the following question: “Will Bugatti build a lightweight vehicle around its iconic 8.0-liter w16 engine? Bugatti Bolide (Bugatti Bolide) The experimental research is a track-oriented super sports car, which is characterized by the use of a w16 engine, which is mass-produced as a powertrain, combined with the smallest body to achieve maximum downforce. Therefore, it is expected to provide the ultimate Bugatti performance.
At the same time, the Bugatti Bolide is the most extreme, uncompromising, fastest and lightest vehicle concept in the company’s recent history-an incredible weight/power ratio of 0.67 kg/PS. This can be done by combining the W16 engine with 1,850 PS and a vehicle weight of only 1,240 kg. The Bugatti Bolide’s figure is almost comparable to Formula 1, while its top speed is far more than 500 km/h without compromising maximum handling and maximum agility. The Bolide takes 3:07.1 minutes to complete the Le Mans lap, and 5:23.1 minutes to reach Nordschleife.
In order to achieve a dry weight of 1,240 kg, whether in the current feasible range or in the future possible range, all stops have been opened in terms of materials and production processes.
All screws and fastening elements of Bolide are made entirely of titanium. In addition, hollow thin-walled functional parts made of aviation titanium alloy are used in many places. Of course, these are all 3D printed and very thin, with a wall thickness of up to 0.5 mm. However, they are still very stable, with a tensile strength of 1,250 Newtons per square millimeter.
Hybrid components (such as a 0.5-meter-long auxiliary drive shaft) combine high-strength and super-hard carbon fiber wound with 3D printed titanium end fittings, which can withstand continuous operating temperatures of up to 260 degrees Celsius. In this example, this reduces the weight by about half to 1.5 kg, and at the same time increases the rotation capacity of the engine due to the reduction in rotating mass. The forces acting on the front and rear wings are transmitted by ultra-light but strong titanium. They weigh only 600 grams in the front and 325 grams in the rear.
Bugatti is no stranger to using 3D printing in final parts. The company has produced some parts through AM, including brake calipers and spoilers.
“Bugatti represents the continuous pursuit of technological innovation-consistent with the company’s brand value of excellence, courage, and dedication. Bugatti never stands still. We are always working on new and exciting goals, and the questions we always keep in mind are: What if?” Bugatti president Stephen Winkelman said. “We asked ourselves, how can the powerful W16 engine be realized in its purest form as a technical symbol of the brand-equipped with only four wheels, engine, gearbox, steering wheel, and as the only luxurious configuration with two seats. The important aspect of our consideration is to fine-tune our iconic powertrain without any restrictions on the weight/power ratio. These considerations have led to the Bugatti Bolide. Uncompromising experimentation, pure blood and pure San S, with its cruelty The exclusivity, with its high performance, light weight and brand new driving experience, makes a deep impression. Driving Bolide is like riding a cannonball.”
“In terms of technology and organization, Bolide is one of the most ambitious projects in my career,” Frank Götzke said. After playing a key role in the development of Veyron 16.4 and Chiron, the engineer was also responsible for Bolide’s technical concept. In just eight months, he built a brand new car around the famous Bugatti W16 all-wheel powertrain, which was heavily modified for the project.
The core of the 8.0-liter W16-cylinder engine is 1,850 PS and 1,850 Newton meters of torque. Bugatti specifically designed the drive used on the track and optimized the engine and gearbox, especially to increase the engine speed. Among other things, this includes throttling the intake and exhaust systems to achieve faster, more natural and extreme response characteristics. The four newly developed turbochargers are equipped with optimized blades to establish greater boost pressure and power at higher engine speeds. In order to achieve the best lubrication effect even under extremely high centrifugal force, the oil circuit, oil pressure, check valve, baffle, oil tank, oil tank and pump design for dry oil tank lubrication have been optimized. At the same time, the weight of the drive system is also greatly reduced.
Bugatti Bolide (Bugatti Bolide) replaces the water-to-air intercooling, but uses water to pre-cool the air to cool the air to achieve the best performance on the track. Air intake takes place from the front through an internal and external air duct on both sides of the vehicle. The two water coolers arranged in front of the front axle provide a more efficient radiator system in terms of flow rate than the convention in Formula 1. Three air-cooled oil coolers for the engine, gearbox and differential with pre-water differential. Even on race circles with high dynamic requirements, cooling will reduce the temperature. The newly developed hybrid carbon-titanium turbofan radial compressor ventilates and cools the high-performance racing brake system.
The Bugatti team developed a lightweight monocoque shell made of carbon around the drive. The entire front end of the flange connection is also made of high-strength carbon fiber, as are the underbody and the monocoque itself that give full play to the aerodynamic effect. The single fiber tensile strength of the fiber used is 6,750 Newtons per square millimeter, and the single fiber stiffness is 350,000 Newtons per square millimeter. These represent figures only available in the aerospace industry. The rear frame is designed as a welded steel structure. Although the wall thickness is only 1 mm, the maximum tensile strength is 1200 Newtons per square mm-this can be achieved by using high-strength stainless steel, otherwise it can only be used for aviation.
The total height of the Bugatti Bolide is only 995 mm, which is exactly the same height as the historic Bugatti Type 35, depending on the steering wheel and truncated windshield, and is about 300 mm flatter than Chiron. The wheelbase is 2.75 meters and the width is 1.99 meters. Just like in the LMP1 racing car, the occupant folds the doors at an angle. These doors are hinged to the front at an angle, sit on a threshold that is only 70 mm wide (such as Type 35), and then put their feet inside. Since the side wall is about 150 mm lower than the 35 type, the process becomes quick and easy-suitable for drivers whose body height does not exceed 2 meters.
For Achim Anscheidt, Bugatti design director, the experimental research of Bugatti Bolide is also a very special project. “In the 16 years I have worked in Bugatti, I have never tried a more extreme concept.” Bolide’s design is completely tailored to the concept of lightweight structure, so its design principle is based on achieving 0.67 kg per unit. PS’s eye-catching weight/power ratio is the primary goal.
The aerodynamically favorable overall height of only 995 mm clearly shows the amazing effect of the overall ratio. The driver’s ultra-sports seat can keep the car’s low-flying aircraft in a low-swing shape. Therefore, it is not surprising that the appearance of the Bugatti Bolide evokes the so-called X-plane of aviation history and displays a clear X signature from all angles. It indirectly reminds people of the Bell X-1 jet aircraft boarded by Captain Charles Chuck Yeager in 1947, the first person to break the 1.06 Mach sound barrier. Bugatti Bolide “X-periment” has an aerodynamically optimized, uncompromising racing shape, and has ultra-sports, the most advanced performance-no sense of luxury.
The Bugatti Bolide is an unparalleled technical concept of a Bugatti supercar focused on the track. The combination of 1,850 PS and 1,240 kg dry weight ensures an incredible weight/power ratio. As far as the internal combustion engine used in automotive engineering is concerned, this puts Bolide’s W16 engine at the absolute peak. “This is the first time we have demonstrated what the W16 engine really has. We have liberated all the luggage of the vehicle, illustrated the engine and combined it with the lightest possible chassis to create the ultimate Bugatti and ensure the ultimate Driving experience. With Bolide, we showed Bugatti fans all over the world the interpretation of modern Bugatti rail cars, and finally realized their strongest desires,” Winkelmann explained.
Whether Bugatti Bolide will be put into mass production is yet to be determined. AM can also help here now.
This 170-page research report from 3dpbm Research provides an in-depth analysis of each major sub-segment in composite AM. The market will grow to 10.6 billion USD…
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Post time: Nov-26-2020