In 2017, GF Machining Solutions Ltd (GFMS) — the EDM, three- and five-axis machining centre and laser machine tool
and automation solutions’ specialist — supplied the Renault Sport Formula One Team with four new high-performance
five-axis machining centres.

These machines — two Mikron HPM 800Us and two Mikron HPM 1350Us — have been installed at the Formula One team’s manufacturing facility in Enstone, Oxfordshire, where they are producing a range of high-precision complex
racing-car components made from difficult-to-machine and challenging materials that include high-grade titanium alloys.

The team’s investment in machine tools from Coventry-based GFMS (www.gfms.com/uk) reflects the Technical Partner relationship that exists between the two companies.

Machine shop manager Raphael Willie said: “We regularly invest in machine tools from GFMS. A few years ago, we decided to increase our five-axis milling capabilities and again selected the company, as our Technical Partner relationship allows us to acquire the latest Mikron machines at highly competitive rates — and have direct access to GFMS’s technical and applications expertise.”

It was decided in early 2017 to trade in a Mikron HPM 600U machine (acquired a few years earlier) against the purchase of two new HPM 800U models, giving the Renault team 10 Mikron five-axis machines at its disposal.

Mr Willie said: “The HPM 600U was a good machine and was universally liked by both operators and programmers, but because we needed to increase our machining capacity and flexibility, we decided to invest in two larger Mikron
HPM 800U machines, which have a similar layout and control technology — and they can use the same part programs.”

The HPM 800Us are being used to produce a diverse range of parts, including front and rear suspension uprights and roll hoops. They have also been heavily involved in machining a number of gearbox inserts made from titanium.

These are new components, and they reflect the Renault team’s decision for the 2018 season to use a carbon-fibre main case for its gearboxes, rather than the investment-cast titanium ones used previously.

More than a gearbox

Mr Willie said: “Gearboxes, which are electronically controlled, hydraulically activated and attach to the back of the engine, do more than simply transfer the torque from the power unit to the wheels; they also form part of the structure of the rear of the car, with the rear suspension bolting directly onto the carbon-fibre main case.

“Moreover, inside the gearbox are a number of performance-critical inserts, including a front top-mounting part made from high-grade titanium. This is machined from solid on one of the HPM 800U machining centres.”

The titanium used for this gearbox insert starts as a 450 x 230 x 123mm billet; and apart from some wire EDM profiling operations, which take about 12hr to complete, the parts are five-axis-machined entirely on an HPM 800U in five separate milling operations.

These comprise initial work-holding/fixturing operations (2hr), followed by two roughing operations (20hr) and two lengthy finishing operations (over 40hr).

“The gearbox inserts are demanding applications, with over 85% of the titanium removed during the roughing and finishing operations — the latter achieving high levels of accuracy and surface finish.

“Furthermore, because we work to extremely tight and non-negotiable deadlines, it was critical to do everything in our power to reduce part cycle times in order to assemble ‘finished’ gearboxes for dyno testing — an on-going and evolutionary process that invariably results in ‘tweaks’ being made to the original design specification.

This has been the case with the gearbox inserts, and the HPM 800U has machined a number of these, as the part has been developed.”

Latest regulations for F1 cars

It may appear to the casual observer that the F1 car regulations for the 2018 season have remained relatively unaltered from last season, with just one exception — the confirmation from the FIA that teams would be required to incorporate the Halo head protection device in their cars.

Although this has grabbed most of the headlines, the decision by Renault Sport Formula One Team to significantly redesign its gearboxes clearly put pressure on its in-house design and manufacturing operations. Testing in Barcelona started on 26 February and the first race is in Australia on 25 March.