• Q.Order books open for second-gen Ford GT

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    Praveen
    Praveen | 8 years ago

    [USER="20"]NikilSJ[/USER] This is quite informative. I wonder why Citroen chose a boring looking wheel design after implementing such a revolutionary technology. Maybe they are trying to be discreet about it? Also, the amount of testing and development that has gone into the carbon wheels of GT 350 R feels way more interesting than the development of the whole car itself! :p

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    Nikil
    Nikil | 8 years ago

    [QUOTE=Praveen;n10427][USER="20"]NikilSJ[/USER] Apparently, Koenigsegg is the first car manufacturer to make carbonfibre wheels. They use the prepreg- type carbonfibre in their One:1, where the fibre material is already impregnated into the epoxy resin and is partially cured. After the material is shaped, it is then cured using an autoclave or an oven. The advantage of pre-preg carbonfibre is that it offers phenomenal strength and resilience and is often used in aeronautical and aerospace industries. Koenigsegg's wheel are made up of a single carbonfibre unit and weighs just 6 kilos! Watch the video by /Drive on how the One:1's wheels are made: [video=youtube;PGGiuaQwcd8]https://www.youtube.com/watch?v=PGGiuaQwcd8[/video][/QUOTE] Apparently, Koenigsegg is not the first car manufacturer to make carbonfibre wheels! The first car that debuted carbonfibre wheels for rallying purposes was on a French car. This Citroen SM with CFRP wheels developed by Michelin won the 1971 Rally of Morocco. So it was basically the French who had the idea of making carbonfibre wheels and not the Swedes as believed. [IMG]https://upload.wikimedia.org/wikipedia/commons/thumb/e/ec/R%C3%A9tromobile_2011_-_Citro%C3%ABn_SM_Rallye_du_Maroc_1971_-_003.jpg/1024px-R%C3%A9tromobile_2011_-_Citro%C3%ABn_SM_Rallye_du_Maroc_1971_-_003.jpg[/IMG] The world's first mass produced carbonfibre wheels too were not produced by Koenigsegg. That claim lies with Carbon Revolution, an Aussie company, and Ford. Carbon Revolution is the first company to perfect the technology to make carbonfibre wheels. They are under a contract with Ford to supply carbonfibre wheels for the Mustang 350-R and Ferrari-fighter Ford GT. Ford heard about the start-up by chance three years ago and then started torture testing the wheels which included hitting pot holes at 100kmph to see if the wheels would shatter. Needless to say, these wheels passed the tests. Jake Dingle, chief executive officer of Carbon Revolution says, "No one has been able to do what we've been able to do. Even the aerospace industry couldn't figure out a way to do it." He seems to be a pretty confident man doesn't he. Both companies haven't revealed how much these wheels cost but expect it to be much more dearer than the regular alloy wheels. Ford Performance also put out a release saying [QUOTE]Ford Shelby® GT350R is the most track-capable Mustang ever and the first vehicle from a major automaker to offer carbon fiber wheels as standard equipment [LIST] [*] [*] [/LIST] With a little help from Space Shuttle technology, Ford helped reinvent the wheel. For the all-new Shelby® GT350R, the most track-ready road-going production Mustang ever, Ford dreamed of using the ultimate high-performance material for its unique wheels – carbon fiber. But while the automotive aftermarket and a low-volume supercar manufacturer have offered carbon fiber wheels, Ford and Australian supplier Carbon Revolution took on the challenge of crafting the first mass-produced, track-capable carbon fiber wheels as standard equipment for Shelby GT350R. Designed, developed and tested with the highest of quality standards in mind, these first-of-a-kind wheels deliver unprecedented chassis performance, massive weight savings and improved driving dynamics. In early testing with benchmark vehicles, prototype wheels showed significant potential – improving suspension response times, chassis dynamics, steering feel and ride quality. When the decision was made to pursue this technology for use in a production vehicle, the engineering team was challenged to develop a wheel that met Ford’s strict standards for durability, quality, craftsmanship and premium finish. Why carbon fiber?Among sports car enthusiasts, carbon fiber wheels are on the short list of dream components for high-performance vehicles. In the rarefied world of supercars only Koenigsegg has offered optional carbon fiber wheels. Lowering overall curb weight in general is beneficial to a car’s dynamics, but a reduction in unsprung weight (those components not supported by the suspension) can have a significant impact on handling and performance. Less unsprung weight helps vehicles start, stop and turn faster by reducing wheel rotational inertia, dramatically improving response time to driver input. Lower unsprung weight also translates to suspension components not having to work so hard to keep the tires in contact with the road over undulating or broken surfaces. Developing new benchmarks Although Carbon Revolution has been the leading manufacturer of carbon fiber wheels, both Ford and the supplier recognized significant innovation was needed to meet Shelby GT350R program needs. This project would set the standard for mass-produced carbon fiber wheels. Ford sets extremely high testing requirements for its wheels. Ford wheels must endure tests that include curb strikes, UV and chemical exposure, and extreme heat durability testing. The GT350R wheels would need to fulfill all of these demands in order to proceed to production. A common misconception of carbon fiber is that while it’s strong, it’s also a brittle material. Some formulations may have this characteristic, but carbon fiber’s durability is a feature of the type of resin and design intent of the part. The wheels of Shelby GT350R are designed to be stiff, light and resilient. One of the most severe tests for wheels in the Ford development process involves striking a curb at speed – a test that, without proper design, can cause serious wheel and tire damage. Because of the light weight, advanced construction methods and resins in the wheels, along with the highly-developed MagneRide dampers, the suspension was able to react so fast that the driver wasn’t sure the test had been carried out correctly and ran it twice to be sure. The suspension response was fast enough to greatly diminish the severity of the impact – that’s the power of minimizing unsprung weight. During track testing the extreme performance capabilities of the braking system developed heat which required the maximum technology available from Carbon Revolution. When brake temperature measurements were taken, it was revealed Shelby GT350R’s ultra-powerful brakes were creating rotor temperatures in excess of 900 degrees Celsius. As a result, the wheel design was elevated from a road car specification to a thermal standard more suitable for motorsports. For decades aerospace companies have treated turbine blade materials subject to extreme heat with ceramic coatings to help improve durability. The technology is also used in top-tier open-wheel racing environments. Athermal barrier coating system developed by Carbon Revolution uses this same technology. Created specifically for motorsport and aerospace applications where extreme temperature conditions are encountered, Carbon Revolution’s thermal barrier coating system uses a multistage, multimaterial coating formulation that provides an excellent thermal barrier. Using a plasma arc gun to liquefy a ceramic material, the wheels are coated at critical points around the inner wheel “barrel” and on the back of the spokes. The result is an incredibly thin, nearly diamond-hard coating that reliably shields the resin from heat – reducing maximum wheel temperatures and allowing continuous track use by even the most aggressive drivers. But that’s not the end of the story with regard to testing. Upon extreme exposure to harsh UV environments, corrosive salts and road chemicals, it became apparent that to achieve the durability required by Ford, a special coating would need to be developed to protect the resin from the environment. Carbon fiber parts are notoriously challenging when it comes to delivering a flawlessly smooth painted surface – the kind of finish Ford demands for all of its vehicles. Several proprietary new processes were developed that resulted in a robust, high-gloss black finish that not only looks good, but ensures a long life for the wheels. Produced to high standards – tested to ensure qualityManufacturing carbon fiber wheels begins with the creation of the preformed internal carbon structure, composed of precisely manufactured carbon strands arrayed into woven fabrics. The elements are then placed into a mold using state of the art manufacturing techniques. An RFID chip with a unique tracking number is embedded in this structure, and each wheel is individually entered into a quality assurance system. Once this structure is assembled, it’s infused with resin and cured at high temperatures. This process results in a one-piece wheel that ensures maximum strength – eliminating the need to bond or glue the wheel’s spokes and barrel components together. As the wheel cures, 61 individual checks and more than 246,000 data points are logged before it’s released from the machine. To guarantee quality parts, the cured wheels are analyzed using a 3D computerized tomography (CT) imaging process in which more than 18,000 X-ray images are taken. If the wheel passes inspection, it undergoes machining for the valve stem and mounting hardware holes before it gets painted, coated, assembled, dimensionally checked and shipped to Flat Rock Assembly Plant for installation on a new Shelby GT350R Mustang. Superior performanceThat the new Ford Shelby GT350R Mustang will be rocketship-fast should come as no surprise, but by cutting the weight of each wheel nearly in half compared to an equivalent aluminum wheel (18 pounds versus 33 pounds), handling and acceleration performance see serious benefits. The wheels also provide a reduction in rotational inertia of more than 40 percent, which positively impacts acceleration and braking performance. The wheels are so light, the springs and MagneRide dampers had to be recalibrated because the suspension can respond considerably faster to road inputs. “The GT350R wheels and tires were developed to be the most track-capable parts we’ve ever produced,” said Adam Wirth, chassis supervisor, Ford Performance. “The carbon fiber wheels reduce vehicle weight by 60 pounds compared to aluminum, yet are stiffer for better steering response. “We believe this is a game changer for the industry,” he added, “a great example of improved performance through innovation.” [/QUOTE]

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    Nikil
    Nikil | 8 years ago

    After initially deciding that they would only make 500 units of the GT over next two years, Ford has now decided that it will increase the production to four years. This could be because of the overwhelming applications it received. Ford says they received 7,000 applications for a car whose production run was supposed to be limited to 500 cars or250 cars a year. Though Ford hasn’t given out an official number, this decision effectively means that the American car maker will make close to 1,000 units of the supercar. Dave Pericak, global director of Ford Performance said, While we can’t build enough Ford GTs for everyone who has applied, we are going to produce additional vehicles in an effort to satisfy more of our most loyal Ford ambassadors We want to keep the Ford GT exclusive, but at the same time we know how vital this customer is to our brand”. Well said, Dave. According to the new plan, year three of production will support applicants who were placed on the wait list. Applicants who were rejected earlier and those who missed out the first time can apply again in early 2018. Those who applied the last time around, meanwhile, will only need to update their request.

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