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For a Formula One team, the speed off the track is as important as the speed on the track. That's because rapid engineering has produced more upgrades, making cars faster and providing drivers with an elusive "unfair advantage", as described by the late driver/engineer Mark Donahue in his 1974 book of the same name of.
The Alpine F1 Team (previously known as Renault F1 Team) uses Volume Graphics' VGSTUDIO MAX analysis and visualization software to maximize the efficiency of engineers when developing better parts to make faster cars.
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The team's non-destructive testing laboratory at its headquarters in Enstone, England, has seen the ability to analyze CT scans of parts to test their integrity without damaging the parts. Adrian Talbot, Alpine's director of non-destructive testing, points out that this capability is a key speed advantage for the team. "It is crucial for us to know that that part is correct, uniform and suitable for use," he explained.
"Completing this work within the time frame Volume Graphics allows us to handle is very beneficial to our team. Using CT and using Volume Graphics software on standard components, it takes 20 minutes," Talbot continued. "Using current methods, such as ultrasound, the entire project may take a day. Therefore, in our non-destructive testing facility, we have never had the ability to detect so many different materials in one method."
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This test is critical to the team’s ability to troubleshoot and understand part limitations. He said: "This also gives us a deeper understanding of the reasons why certain things failed."
Members of the Volume Graphics Alpine F1 fleet's non-destructive analysis team can use VGSTUDIO MAX to study the inside of parts without having to cut them open for inspection.
Members of the Alpine F1 Team non-destructive analysis team can use VGSTUDIO MAX to study the inside of parts without having to cut them open for inspection.
Talbot asserts that this speed not only helps the parts, but also helps the organization of the Alpine F1 team. "This will obviously help us develop our own processes internally and create a freer and faster process environment within the non-destructive testing department."
Engineers can break through the limits of using VGSTUDIO MAX, because the software allows them to more clearly understand the safety margin when doing so. "Using Volume Graphics in our department is building a level of confidence that we may not have seen before," Talbot said. It provides you with dimensional accuracy. It gives you a deeper understanding of the whole part. With that comes confidence. "
Formula One teams are generally reluctant to talk frankly about their car parts because they are afraid of providing a competitive advantage to rival teams. But Alpine is willing to talk about its use of VGSTUDIO MAX to study several less sensitive components, namely the 3D printed titanium pitot tube that measures airspeed and the carbon fiber brake pedal.
The volumetric graphics are carefully checked by the CT scanner and VGSTUDIO MAX software, there is no secret in the internal passage of the 3D printed titanium pitot tube
Under the inspection of CT scanner and VGSTUDIO MAX software, there are no secrets in the internal passage of the 3D printed titanium pitot tube
Additive manufacturing allows the manufacture of parts with complex internal structures, but the Alpine F1 team needs to ensure that the internal channels of the pitot tube are manufactured as designed. "There are very, very small holes where you can assess the air pressure when the car is driving along the main straight of the track," Talbot explained. "Before applying it or connecting it to a car, we must know that every channel in the pitot tube is not blocked, has a good surface finish, and the overall integrity of these tubes is intact, which is very important."
The importance of the brake pedal is self-evident. The team wants to minimize its weight, but obviously, the pedal must not malfunction. "We have made great progress in ensuring that the compound brake pedal is rigorously tested," he said. "Because we can separate the parts digitally, we can basically cut the parts in half instead of actually cutting the parts in half. This has brought a lot of feedback to our relevant departments."
Christof Reinhart, CEO of Volume Graphics, said that the engineering analysis speed and confidence advantages of VGSTUDIO MAX software have been amplified in environments such as Formula One, but they are applicable to various industries. "The racing car is the essence of Volume Graphics: speed, precision and excellent engineering design. Many customers all over the world use our software every day to inspect the most advanced and complex parts. But high-performance sports like this require us. To new, previously unknown limitations. Overcoming these limitations will not only help the Alpine F1 team, but also all of our other customers."
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