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C.R.P. Technology and the
Motorbike World Championship… the project goes on…
CRP Technology, brilliant brand in the racing world, since more than thirty years creates high precision mechanical components as supplier for Formula one, WRC, America’s Cup and motorbikes international teams.
During 2005 the company begins the great challenge of the racing motorbikes, facing the worldwide market with a MotoGP 250 cc class bike, completely built by the CRP technical staff and that has lined up at the World Road Championship 2 bikes with the Fantic Motor brand.
The bikes were ridden by the 125 class world champion Arnauld Vincent and the young Gabriele Ferro.
The teams were strongly impressed by mechanical parts made by the means of the SLS technology (selective laser sintering), that allowed to reach the track within incredibly short timing.
Even if the quick line up had been penalized by the races results, it has to be underlined that the race tracks have been the first test tracks at all.
For 2006 season, CRP has decided anyway to continue the project development away form the racing and media eyes, in order to show, in 2007, a more competitive bike.
The schedule is based most of all on the engine development, that needs a high step forward to get closer the top level of racing.
The CRP technical staff is endlessly working in order to refine the last 2005 engine release test and to go on with the new 250 cc quite advanced engine project.
The design is developing accordingly with the technological innovation; the technology – coming form F1 world – used in 2005 to manufacture mechanical parts in incredible quick timing, are going to be adapted to the motorbike racing needs.
Referring to what above, have a look to the following scheme, that is about the manufacture and evolution of the 2 cylinders racing engine.
Traditional process
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Innovative process
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step
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remarks
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step
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remarks
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| wooden pattern of the cylinder external shape |
Machined pattern. Usually very simple geometry has to be designed in order to avoid problems due to model getting out of shape.
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CAD model of the cylinder |
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| core box pattern for internal ducts |
It's one of the main parameters that define the 2 strokes engine performance. It's necessary to reach a compromise between the geometry complexity and the limits of the process. The ducts must get out of shape without failures.
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cylinder made by Rapid Prototyping technology
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it allows the assembly of the cylinder to verify the geometry and the right location on the bike. It’s possible to make a prototype of the rough casting in order to machine it to obtain the finished part. In this way, it’s also possible to set up the machines Numerical Control program.
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| engine cylinder sand casting |
this casting is usually cheaper, but it’s necessary to optimize the process step by step to obtain good castings.
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ducts testing with flowmeter
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prototyping all ducts, they can be optimized by flowmeter tests
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| heat treatment |
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eventual cylinder 3D file update
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| CNC machining |
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rapid casting
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this technology allows to cast complex geometries without taking care of undercuts and drafts.
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| hand update of the internal ducts to increase the performance |
in order to be adapted to the wanted geometry
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CNC machining
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they are very fast because the programs are already optimized
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| finished cylinder |
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finished cylinder
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| torque dynamometer engine test |
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torque dynamometer engine test
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results verify wanted performance
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| updates to reach performance |
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updates to reach performance
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based on simulation and practice testing processes
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| update of the cylinder pattern to update the casting |
the update has to be done on the first pattern and this could force a complete new manufacture of the core box for the ducts. It could be also need a new project of the core box assembly and it could take different external overall dimensions. It’s also difficult to be sure to make again the same hand update loosing the repeatability of the performance
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update of the CAD model and new check
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the update to reach the performance and the check are made directly by CAD. The path already gone is maintained
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Table 1 – comparison between traditional process and innovative way to manufacture a racing 2 strokes engine cylinder.
Looking to the table, it’s clear how far is the new project approach: the designer has much more time and freedom.
CRP goal, whilst looking for R250 optimization, is not only the search for performance, but also the development of the Rapid Casting and Rapid Prototyping technology in order to perfect suit the motorbike world.
These processes allow a really high repeatability of the mechanical components and, consequently, a deep analysis of the performance and a detailed study description of each part and its own evolution.
Study layout
Dr. Eng. Simone Boninsegni
Resp. progetto 250cc
CRP Technology
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; "CAD File")
