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High Performance Steel Requirements for a NASCAR
High Performance Steel Requirements for a NASCAR Race Team Tommy Wheeler Technical Director, Engine Development Evernham Motorsports THE POWER OF #1 Spectator sport 17 of the top-20 attended events in the U.S. #1 Sport in fan brand loyalty #2 Rated regular-season sport on television 75 million fans 60% Male, 40% Female Over $2 billion in licensed sales annually 10-month season from February – November More Fortune 500 companies than any other sport NASCAR events typically add $100-$200 million in local and regional economies Larger crowds than a Super Bowl, NBA Finals game, and World Series game combined Televised weekly in more than 150 countries around the world in 32 different languages • VIDEO 2006 RACE TEAMS Cup Series Busch Series Truck Series ARCA Series Team Evernham Motorsports Ray Evernham Team Owner Legendary Crew Chief Three Championships as leader of the No. 24 Rainbow Warriors Highest NASCAR winning percentage as a Crew Chief Chosen by DaimlerChrysler to bring Dodge back into NASCAR racing after 20+ year absence Has put Dodge in the winner’s circle ever year for his five years as an owner Kasey Kahne No. 9 Driver 2005: One Cup Victory, 2 Busch Victories, 5 Pole Awards 2004 Rookie of the Year Voted 3rd Most Popular Driver 3rd in mass merchandiser sales 5th in at-track merchandise sales Jeremy Mayfield No. 19 Driver 9th in Points 2005 Race for the Chase Participant 2004 Race for the Chase Participant 2004 USA Today Most Improved Driver Scott Riggs No. 10 Driver Won the Pole at Martinsville (2005) Busch Series Rookie of the Year Busch Series Most Popular Driver Two NASCAR Busch Series Victories & Five NASCAR Truck Victories Erin Crocker No. 98 Driver USAC 2003 National Rookie of the Year Winner of a World of Outlaws Feature in 2004 Pole Winner at her first ARCA race Pole Winner at her third ARCA race Two second place finishes and an average finish of 3.5 in six ARCA starts Qualified 9th in her second NASCAR Busch Series start Featured stories in NY Times, USA Today, Chicago Tribune & Time Magazine 2005 Racing Performance • Two (2) Nextel Cup Wins (Kasey at Richmond & Jeremy at Michigan) Note: Evernham Motorsports had 2 of the 3 Dodge victories in 2005 • Two (2) Nextel Cup Poles (Darlington & Richmond) • Two (2) Busch Series Wins (Kasey Kahne at Texas & Kansas) • Three (3) Busch Series Poles (Phoenix, Richmond & Charlotte) • Two (2) ARCA Pole Awards (Erin Crocker at Nashville & Kentucky) • One (1) “Race for the Chase” car (Jeremy Mayfield) • Nextel Pit Crew Champions (EMS has won the last 2 championships) • • 300+ Team Members Strong State-of-the-Art Facilities • Nextel Cup & Busch Series Programs - Statesville, NC Truck Series Program – Mooresville, NC Evernham Engines - Concord, NC Advanced Engine Technology Northhampton, England Evernham Partners A Cutting Edge Philosophy Technical Leadership • Evernham Motorsports is a technical leader within the NASCAR community pushing the use of engineering and advanced technology. The entire organization from the top down is dedicated to using an engineering process to develop our race cars and race team. Objectives as a Race Team • Challenge as a race team – we have several objectives • Win races • Win championships • In addition, we must • • • • Represent partners Create business to business relationships Maximize licensing revenues Create exposure for global brands • By definition, to win we must beat all competition to the finish line. To do this we must • Be a technical leader • • • Develop cars, engines and people faster • • Push the envelope to find performance gains others cannot Leverage business-to-business relationship to create win-win opportunities with technical partners Time is critical, races start with or without you each week Respond to changes quicker Ultimately Evernham Motorsports is a race team with the purpose to win championships and the product is PERFORMANCE. Objectives as an Engine Manufacturer • Produce Engines for four different race series • • • • • 5 NASCAR Cup Programs • Over 290 engine builds 6 NASCAR Busch Series Programs • Over 150 engine builds 2 NASCAR Truck Series Programs • Over 50 engine builds 1 ARCA Series Program • Over 10 engine builds Over 500 Engine builds to support the Racing Effort Objectives as an Engine Manufacturer • Develop Engines capable of Winning at the highest levels of competition • Implementation of up to 9 different engine packages in the Cup Series Per Season • Implementation of up to 5 different engine packages in the Busch Series Per Season • Each Package targets specific performance, packaging, operation or durability related goals Objectives as an Engine Manufacturer Maintain the highest level of durability possible • Due to the nature of the race series a compromise in durability is not possible Objectives as an Engine Manufacturer Operate as a separate business unit • Provide exceptional value to each “customer” • Service • • • • • Track side support Engineering assistance Reliability Performance Operate with strict budget constraints • Minimize Overhead and maximize output Evernham Motorsports is a car manufacturer We build the majority of the vehicle in-house • • • • Chassis Suspension systems Engine Body We require a broad range of capabilities • • • • • • • • Mechanical Design Surface Design Manufacturing Reverse Engineering Structural Analysis Kinematic Analysis Machining, included advanced 5-axis Data management and portability Unique Challenges in NASCAR In NASCAR, unique challenges are presented that require advanced engineering. • Schedule – 39 races from February through November • Tracks – Superspeedways, Intermediates, Short Tracks, Road Courses • Design differences between cars • • • Rule changes during middle of season • • Common for NASCAR to change rules during mid season NASCAR Restricts Track Testing • • Each type of track requires a purpose built car For 2006, Evernham Motorsports will have over 65 race cars Places a premium on engineering and simulation Level of Competition • Difference between first and last place is fractions of a second Team Structure and Focus Team is structured and focused on improving physical factors that increase vehicle performance: engine power, aerodynamics, tire grip • Technical focus is on predictive simulation and design • Aerodynamics • • • • Chassis & Vehicle Dynamics • • • 40% scale model rolling road testing Computational Fluid Dynamics (CFD) surface preparation Surface quality control Evernham chassis design and development Suspension component analysis Engine • • Engine Manufacture, development and integration High-end Design Resource and manufacturing Aerodynamics • CFD Program 40% scale model program • • Full Scale Wind Tunnel Testing • Track Testing Aerodynamics Chassis • Chassis Features • • • • Lighter Stronger Lower c.g. Adjustable suspension geometry • • • Optimized performance at different tracks Underbody aerodynamics Tubing is CNC bent and laser trimmed for efficient and accurate construction Engine • Several Engineering Challenges • • • • Produce lighter components Produce stronger components Produce engine components with repeatable fatigue limits Design cycle times are extreme with an endless cycle of designing, analyzing, and machining dozens of times daily. Engine • Meeting our engineering challenges • • • • • • • • Solid Modeling Structural Analysis Fluid Analysis Engine Simulation • Including Co-simulation Performance related test fixtures Durability and fatigue test fixtures High speed, High quality manufacturing techniques Quality control and failure analysis Engine Engine Engine Engine Steel and Uddeholm Why Steel? • Design Potential • Rule Limitations • Ease of Manufacture • Material Availability Steel • Design Potential • Nearly the entire NASCAR vehicle is comprised of Ferrous alloys. • 3400 lb ~ 80% Steel = 2720 lb of possibilities • High Specific Strength • Wear Resistance • Repeatable processing and heat treatment NASCAR Mandates • Rule Limitations • NASCAR mandated “Magnetic” materials within the engine • Connecting Rod • Crankshaft • Camshaft • Valve Spring • Camshaft Follower • Flywheel • Pushrod • NASCAR mandated weights within the engine • Connecting Rod • Piston Pin Steel • Ease of Manufacture • Great experience with manufacture of steel components • Ratio of mfg to strength • Technical link with the steel manufacturer with regard to manufacturing techniques and tooling • Improved throughput • High quality, High yield mfg Steel • Material Availability • Repeatable purchasing, and JIT manufacturing techniques • Reduced development cycles based on short lead times of steel • Increased stocking due to relative low overhead expense in material • Improve response to development needs (real time) • Wide range of alloys available for various needs Steel • Why Uddeholm? • Specialty alloy selection for various engine components • Ex. Crankshaft vs. Camshaft • Constant development philosophy • Accessibility to vast expertise in alloy selection, design, processing and manufacturing Case Study - Retainers • Initially Valve spring Retainers were comprised of Titanium (Ti6Al4V) • • High component cost (~$12.50 USD each) Coating Required (~$2.00 USD each) • Experienced high component wear which led to performance degradation of the engine. • The fatigue limit of the component was around 2.0 million engine cycles • Material Transition • Reduced deflection of the component • Eliminated component wear and resultant loss in performance • Increased fatigue life by nearly 4 times with alloys such as Uddeholm Caldie • Individual Component cost reduced to ~$4.75 USD • Annual cost savings in excess of $62,000 USD • Our environment is characterized by • • • • Extremely short cycle times for design changes Low margins for error High performance manufacturing High tolerance and flexibility for change Evernham Motorsports is committed to being a technical leader in NASCAR racing We Partner With Only the Best, As We Are Committed To Excellence On and Off the Race Track. THANK YOU!
