How to Build a DTM Car
As mentioned previously, Audi Sport will be campaigning an A5 in the DTM series which gets the green flag on April 29 at Hockenheim.
What’s interesting to note is that Audi Sport is building eight cars for the DTM series, which specifies that only new cars can be raced. This is more cars than the team has ever produced.
Said Dr. Wolfgang Ullrich, who heads up Audi Motor Sport, “Developing a new race car for a new set of technical regulations and then duplicating it eight times and assuring the supply of spare parts in the process is a very difficult logistical challenge.”
Each car consists of approximately 4,000 individual parts.
All of the DTM vehicles—whether Audi, BMW or Mercedes—use the same monocoque. Fifty-eight other parts are also common. These parts are non-performance related. The purpose of the common parts is to reduce costs for the teams.
The differences come in the areas of aerodynamics and powertrain and the like.
At the Audi Sport production facility they start the process with the monocoque, then add the front end with the engine; the front crash structure, the rear end with the clutch and transmission; then the rear crash structure.
Then, when all of the cars are built, they begin the production and pre-assembly of spare parts. After all, if there’s one thing true about race cars it’s that they generally go fast and they typically break.
According to Kunihiro Hoshi, chief engineer for the GX 470: “Three of my top goals were to create a body-on-frame vehicle with sweeping off-road performance and unibody-like on-road capability, and, of course, it had to meet the Lexus quality standard.” He met his goals. But why would anyone want to bang this vehicle around on rocks?
Additive manufacturing (AM) is just one manufacturing method that drives advanced mobility forward and also has a history of embracing the digital connectivity demanded by this trend.
By James Gaffney, Product Engineer, Precision Grinding and Patrick D. Redington, Manager, Precision Grinding Business Unit, Norton Company (Worcester, MA)