KRISHNA ENGINEERING COLLEGEMECHANICAL ENGINEERING

DEPARTMENT

A SEMINAR ON

BUGATTI VEYRON - How its made

ByTushar Jaiswal

ABOUT BUGATTI

ABOUT VEYRON

• Only 450 wilI ever be made• A million pounds• 0-60 mph in just 2.5 sec • Unlike any other car ever made• Engine -1001 HP• Most innovative braking system• Magical transmission and shifting system

CHALLENGES FACED BY BUGATTI ENGINEERS

• Monumental challenge- To build an engine with such high power• Technological challenge- To control exessive heat radiaton• Transmission challenge- A unique engine needs a unique transmission• Braking system challenge- The giant car needs massive brakes• Technical challenge- Tires were extremely demanding

MONUMENTAL CHALLENGETHE ENGINE

1001 HP engine - 5 times that of normal car

Needs 2 very different personalities

Beast on race track & Gentle giant in the town

2 V-8 engines were combined to create a giant 16- cylinder monster- THE W-I6 ENGINE

Build in Salzgitter, GERMANY

W-16 ENGINE

ENGINE - How its made

8 specialists - build it by hand All parts are machined out of solid Titanium Carried inside custom padded cases Nearly 3500 parts 16 pistons-carved from blocks of Aluminium Each bolt - tightened by hand & checked by computers 1 engine requires - 1 week

TECHNOLOGICAL CHALLENGETHE HEAT

The W-16 actually produces 3000 HP Two-third of that is lost as heat In first test-exhaust system got burnt Energy wasted could keep 100 homes warm An illegal & unsafe 6 feet flame shot out Car’s exhaust was re-designed using a tested

technology New cooling system built

RADICAL COOLING SYSTEM

o Each radiator is handcraftedo 600 separate grooves for water to flow througho 1 radiator consists – 30 separate plates stacked > welded together > pressure tested to ensure no leakageo 1 radiator takes 15 hourso A Veyron has 10 such radiators

TRANSMISSION CHALLENGETHE ACCELERATION

With 16 cylinders sucking in more fuel and air than any other car in the world ,it was sure to produce uniqe sound and acceleration

Transmission shifts in 150 ms 2 transmissions were built into 1 A DOUBLE CLUTCH TRANSMISSION was

introduced with 2 INPUT SHAFTS A manual transmission controlled by computers

BRAKING SYSTEM CHALLENGE

A Veyron can stop faster than any production car in the world because of its incredible combination of 2 Braking systems-

MECHANICAL BRAKING SYSTEM & AIR BRAKING SYSTEM

MECHANICAL BRAKING SYSTEM Massive disc brakes- High-tech Carbon,Ceramic & Titanium Each part is handmade Raw materials are Hand-moulded Next ,they are polished & secondly baked Drilled & assembled Can work at 900 ⁰C while other disks stop at

700 ⁰C

AIR BRAKING SYSTEM At speeds > 125mph ,VEYRON rear wing shoots

up to 55 degree angle It generates 70% of braking power For normal driving wing is retracted Hit 135 mph ,wing pops up to 15⁰ angle For speedy runs(> 230mph),wing retracts to 2⁰ it provides safety & stability during braking and

accelerating period

ALL OVER EFFECT Fwing + Fdisks = 2 G

(0 to 60 mph) in 2.5 sec

(60 to 0 mph) in 2.2 sec

(253 to 0 mph) in 10 sec

WING- How it works Wing depends on tiny sensors These sensor units are manufactured by

MTS- a high tech company, in Germany the sensor measures the time it takes for a

pulsive light to travel down a wire,hit a magnet and reflect back as an ultrasonic soundwave

Sensor’s performance needs to be quick so that computer system executes accurate angles as needed

TECHNICAL CHALLENGETHE TYRES

No tyre was available to meet the requirements Bigger , infact biggest tyres were designed ever 14.5 inches wide (rear wheel)

Normal car tyre takes – 30 sec BUGATTI VEYRON tyre takes – 1 hour Tyres are made of the rubber used to make

aeroplane tyres A set of Veyron tyre lasts for 6000 miles A set of 4 tyres costs upto £ 11,000

VEYRON TYRE– how its made A handmade tyre Different layers of rubber-rolled over a roller Perfect alignment of layer boundries Checked with laserbeams under Microscope Thoroughly tested on TYRE TORTURE MACHINE It produces every possible force and condition

that the tyre would face on road/track Finally tested on worlds most sophisticated

wet handling tracks in France

BUGATTI VEYRON-ASSEMBLY

17 SPECIALISTS assemble Veyron by handsCarefully move rear frame along with the

wing mechanism into position to bolt it to the Engine & Transmission

Frames are built by HEGGEMANN COMPANY which builds frames for Aeroplanes

Gear & middle front section are slowly pushed together by hand

ASSEMBLED BODYThe hoses & electrical contacts are connectedWhen everything is lined up , the car is boltedJust 14 bolts each made of TITANIUM No frame in middle

Passenger compartment is - monocoque construction-just 108 kg

the middle section has enormous strengthJust as the cockpit of an airplane Whole assembly is in carbon fibre

COVERING AND FINISHING

Handcrafted covers on the top of radiators

Aluminium parts are polished ,aligned & bolted to the car

4 to 5 weeks-time span for assembly

Secretly tested on VOLKSWAGON testing track facility in Wutsberg,GERMANY

NUMBERS & FIGURES

At maximum power its turbochargers suck in the same amount of air in 1 min that the driver would use to breath for 4 days

At top speed,Veyron travels 3 miles/gallon fuel

At top speed 26 gallon fuel tank runs dry in just 12 minutes

THE MARVEL IS READYAfter 500 km of road test each car is polished

and inspected in light tunnel for 2 daysWrapped inside a protective cover for shipment

to customersThis AUTOMOTIVE & AEROSPACE combination,

BUGATTI VEYRON is a marvel of MECHANICAL ENGINEERING & an expensive toy for those who want to own a rare piece of mechanical art

SOME MARVELOUS EDITIONS• Soleil De Nuit- 2009..polished Al accents..metallic

blue/black..burnt orange interior..US$2.27 m

Grey Carbon-2010..carbon fibre..metallic grey dark Al body..polished lower portion..

Royal Dark Blue-2010..carbonfibre monocoque, bonnet and rear section in dark blue..rest painted in Arctic White.. €1.75 m

Sang Blanc-2010..request of client..matte pearlescent white with black front grill..GB£1.25m

Matte White-2011..matte white paint finish .. Deep blue tint ..blue interior

L’Or Blanc- 2011..means white gold..blue and white pattern..

Red Edition- 2011..body & interior painted red.. wheels are red..brought in to boost up the sale

Middle East Editions-2011..bright yellow exterior &interior €1.58 m..blue carbon ext.& orange interior € 1.74 m

Wei long-2012..high quality porcelain..pearl white ext. ..carmine red int.

Bernar Venet-2012..on the name of a one-off artwork creator..fastest artwork ever done

THANK YOU