Motorsports Company Reduces Component Production Time With New Programming, Simulation Tools

Frank Jahn (right), responsible for component production at Porsche Motorsport, and Dittmar Lienert, in charge of programming and operation, record the work schedule in CELOS® and document the production.

Situation:

In 2015 Porsche Motorsport took the overall victory at the 24-hour race in Le Mans, won the Manufacturers’ World Championship title, and was crowned the drivers’ World Champions. Because the company needed to produce components for the racing cars more quickly, it needed component production as a new core competence for parts for the Porsche 919 Hybrid.

“Short response times and flexibility are deciding factors for success in the field of motorsports,” said Frank Jahn, the man responsible for component production for Porsche Motorsports. “For this reason, in parallel to the numerous cooperations with first-class suppliers, an in-house production has also been set up. The challenge for this project has been enormous. We had to invest here with regard to technology as well as personnel.”

The range of applications handled in the development department includes the production of undercarriage parts and crankshaft housings, as well as operational equipment, which plays a big part in successful racing.

Also, modifications to any of the numerous components have to occur at short notice between the individual races.

Resolution:

To reduce final production time, the company performs programming in Siemens NX CAM and simultaneous simulation of the programs in the DMG MORI Virtual Machine. This method also reduces errors because any possible collisions are instantly displayed.

A DMG MORI CTX beta 800 turning center and DMU 65 monoBLOCK® 5-axis milling machine form the machine tool equipment part of the resolution.

The process chain includes constructing and programming with Siemens NX CAD/CAM, followed by a 1:1 simulation of the NC program in the DMG MORI Virtual Machine.

“The Siemens NX CAM provides the required programming strategy for even the most complex machining operation. And we check feasibility and ensure 100 percent collision safety with the virtual machine,” said Jahn. “We often need to deliver top results in the form of high-quality components within 24 hours as well.”

The DMG MORI Virtual Machine simulates the programs in Siemens NX CAM in a 1:1 manner.

This is why the complex components must be machined error-free on the first attempt.

With this setup the company can resolve production tasks quickly and reliably.

The turning center is equipped with a Y axis and an oil mist circuit breaker, and the 5-axis milling machine enables the company to create highly complex parts. Both machines have work areas that are sufficiently big for the respective components.

Within the scope of complex component production, the CELOS® user interface on both machines also helps the operators monitor and manage the production of parts.

“Based on photos, we record components as well as clamping devices in CELOS and manage cut edges and tools,” said Jahn. This also helps facilitate the required documentation into production.

“With [this] production chain we program, simulate, and produce any complex parts for our racing cars incredibly fast and error-free. This way we contribute to the head start our teams in Le Mans and elsewhere bring to the racing track,” said Jahn.