In the world of engineering and motorsport, precision is not merely a requirement—it is essential. Each component of a racing car, from the chassis to the drivetrain, must be engineered with meticulous accuracy to ensure peak performance. Any deviation can significantly impact speed, handling, and overall race outcomes.
This year, Vulcanus had the opportunity to contribute to the GET Racing Dortmund project, a student-led initiative at TU Dortmund University that embodies the principle of precision. Our involvement in this project underscores the essential role of advanced engineering in high-performance applications and demonstrates the potential for innovation when academic knowledge is applied in practical settings.
The GET Racing Dortmund Team: Who Are They?
GET Racing Dortmund e.V. is a formula student team of TU Dortmund University. The team is composed of students specialising in various engineering disciplines, including mechanical, electrical, and automotive engineering.
Each year, they take on the task of designing, building, and racing a single-seater car, competing in Formula Student events across Europe. These competitions serve as a rigorous test of engineering skills, innovation, and teamwork.
The initiative provides students with a platform to apply theoretical knowledge, address complex engineering problems, and gain hands-on experience in a competitive environment, thereby preparing them for future careers in the automotive and engineering industries.
The Role of Vulcanus in the Project
Our role in this project focused on manufacturing the planetary carriers and planetary pins, critical components of the vehicle’s drivetrain. These parts are essential for the car’s ability to transfer power efficiently to the wheels and must endure significant mechanical stresses.
Precision in their manufacturing was essential to meet the performance requirements of the racing environment. To achieve this, we utilised our DMG MORI CTX beta 1250 TC, a multi-tasking lathe-milling machine capable of handling various complex machining operations with a high degree of accuracy. By integrating multiple processes into a single setup, we ensured the planetary carriers and pins met the required tolerances and quality standards.
The Engineering Challenge
Manufacturing these drivetrain components presented several technical challenges. In fact, the planetary carriers and pins needed to meet strict performance criteria, ensuring they could withstand the extreme conditions encountered during racing. The tolerances were tight, and the surface finishes required a high degree of precision to minimise friction and wear.
To address these challenges, we used the DMG MORI CTX beta 1250 TC. This machine was employed for both turning and milling operations, allowing us to achieve the necessary tolerances and surface finishes in a single setup. The process involved initial machining on the main spindle, followed by finishing on the counter-spindle. This sequence ensured that the components were machined to the required specifications with high accuracy.
The Manufacturing Process in Detail
The manufacturing process began with the selection of raw materials suitable for high-stress applications. We used the DMG MORI CTX beta 1250 TC to begin the turning process. This shaped the raw material into a form similar to the final component. Next, we performed milling operations to refine the components. This step ensured they met the exact specifications and included the detailed features needed for the drivetrain’s proper function. The machine’s ability to perform both turning and milling within a single setup enhanced efficiency and accuracy.
After the machining phase, the assembly process involved pressing the pins into the planetary carriers. This step required precision to ensure a proper fit, as any misalignment could compromise the performance of the drivetrain. The final assembly underwent a series of quality checks, including inspections for dimensional accuracy and surface finish, to confirm that the components met the specified standards.
The Impact of Our Collaboration with GET Racing Dortmund
Our partnership with GET Racing Dortmund has had a positive impact on their racing performance. Notably, GET Racing Dortmund secured first place in their recent competition, highlighting the effectiveness of their engineering and team efforts. By providing high-quality components, we supported the team and demonstrated the crucial role of precision engineering in high-performance applications.
Such collaborations offer student engineers valuable hands-on experience and insights into real-world engineering challenges.
Advancing Precision Engineering Through Collaboration
Our collaboration with GET Racing Dortmund has been a valuable experience, combining engineering precision with the practical demands of motorsport. It has allowed us to demonstrate our expertise in precision manufacturing while supporting an educational initiative. We look forward to supporting similar projects in the future, recognising the importance of fostering the next generation of engineers.
If you’re passionate about precision engineering and eager to work on projects that push the boundaries of innovation, we invite you to explore career opportunities with us. At Vulcanus, we are always on the lookout for talented individuals who share our commitment to excellence. Check out our open positions and see if there’s a perfect role for you!
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