Bugatti Veyron

How fast do you think the car can achieve ? Reach to notorious top speed.
Bugatti Veyron is the part of airplane as well as part of automobile.The sculpture of speed.
Put it to extreme in every direction. Let me say something that German Engineering is the best.
No wonder Adolf Hitler launched the WWII and tried to dominate the whole world.



Bugatti Engine

Engine CAD
What kind of CAD software ? (CATIA, Pro/E, UG...)

Engine CAD. Piece of art.

W16 Engine. Which engine is the best Ferrari or Lamborghini V12 ?



This is where the engine was built.
Salzgitter Germany about hundred fifty miles west of Berlin.
One of the biggest engine plant in the world.

The bottom of the engine. As you can see the crankshaft has been installed.

What a spectacular engine. Each side of engine which has 8 pistons.

This is absolutely hand made engine.

Piston and Connecting Rod.

Carankpin. Used Titanium as material.

Torque check by computer

Install Crankcase

Piece of Art.
Note that the Cylinder Head, Timing Belt didn't install.

Radiator

Glue the plate

Welded it together.

If you want to pedal to the metal for 1001 horse power.
You need one of a kind transmission.

Transmission

There are two transmission built into one, they called Dual Clutch Transmission.

You have two input shafts. One for even gear, the other for odd gear.
You have two clutches. Each clutch engages on each input shaft.

With two transmission shafts, two gears can be engaged in the same time to shift.
All the car dose is switch the clutch. The shift is the only to change the clutch system.

The Dual Clutch concept is why the transmission can shift so fast.
The car can be accelerated in one gear and already for the next gear.

This is extremely sophisticated device controlled by computer.

Disc Brake. Stopping the car from one third of speed of sound.

Made of high-tech carbon, ceramic, titanium.

Each brake was hand-made by the expert.

The opposite side of disc brake.

Put raw material into the mold. What's the way of manufacturing the disc brake?

Remove the mold plate.

Polish

Drill

Assembly the nut.

Bolt it up.

Disc Brake test.

Working at 1800 degree Fahrenheit.

Bugatti Caliper

Rear Frame.

Spoiler. MTS Sensor company.

Hand made the sensor.

Heggemann. Ship it to there for the test.

Test the rear wing

Weld the chassis

Chassis

Fuel Tank

You need a special tire is almost twice wider than normal passenger car.

Roll the multiple layer of rubber on the spindle.

Laser beam to make sure the alignment of every layer.

Tire Torture Machine.
The machine reproduced every possible force condition that Veyron tire could face on the road.
On this machine they create forces that exceed in fact what is on the track.

Road Test. Too fast to capture it clearly!!!!!!

Simulate every condition of the road from drizzle to downpour.

Bugatti. What an extraordinary facade. Gorgeous and Spectacular!!!!!!

Bugatti Assembly Plant

What a clear working environment ~

Put the rear frame with wing strut and engine into position

The front frame

There is "no grease lift jack", because this is not for typical car factories.
Unlike the regular car, there is no  frame in the middle of Veyron.
The passenger's compartment is built what's called "Mnocoque" construction.
It is like airplane fuselage.

The car ends up in three sections.

The rear and middle frame are pushed together slowly by hand.

The moment of triumph !!!!!!

Just fourteen bolts. Each bolt made of titanium and costs one hundred dollars.

Cool

German engineer looks pretty handsome. Awesome ~~~~~~
Why do they look so superior and excellent ??????

Roll Test

Put the handcraft cover on the top of turbocharger radiator.

Ready to road test.

Cutaway

The moment of man-made marvel come true.

After road test, the car went back to light tunnel for inspect and polish.

Perfect is not good enough. This motto is   German soul of automobile.
Part of Airplane !! Part of Car !!

                                                "Masterpiece of Engineering"

[Highlights]
W16 Engine
Radiator Fabrication
Dual Clutch Transmission
Brake Disc fabrication
Spoiler sensor
Tire fabrication and torture machine
Titanium bolt (just fourteen bolts) How to made it ?
Monocoque  Passanger's compartment

[Questions]


National Geographic Channel. I stand up and salute to you. You are my personal hero.
Without this ultimate factories series, I never know what the true mechanical engineering is.
Thank you very much. Appreciate !!!!!!  Appreciate !!!!!!  

All pictures were captured from NGC.