Bugatti

Veyron
Making Of This Magnificent
Beast
Presented by:

Udayan Vidyanta
B.Tech.
Mechanical 5th Sem
Institute of Technology
Guru Ghasidas Vishwavidhyalaya.

Presented to:
Ms.J.P.Ekka

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Dated:
16th September, 2014.

Acknowledgement
I would like to extend my deep sense of gratitude to my
professor, Ms. J. P. Ekka, who provided me with an
opportunity to speak on such a fascinating topic.
Then, I would like to thank my parents and friends for
believing in me. It means a lot.
Again then, I would like to thank National Geographic
Channel and its programmes..... I literally grew up
watching them. Thanks to them, I developed my
interest in automobiles.
Last, but not the least, a sincere thanks to God and
Google.... without you two my life would be a mess.

Yours Sincerely,

Udayan Vidyanta.

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Contents
S.No.

Topic

Page No.

1.

Aesthetic Principles
Of The Super Sports
Car

2.

Birthplace Of The
Veyron

3.

How the Bugatti Veyron

Works?

4.

Veyron Engine: Heart

of the Beast

5.

Special Features

6.

Chiselling Out The

Body

10

7.

The Tires And Interiors

12

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8.

14

Conclusion : Masterful
Technology

Aesthetic Principles Of The Super

Sports Car
With its luxurious length of 4.47 m, the Veyron is a perfectly balanced
combination

of

high-powered

performance

and

sleek,

racy

design.

Even at complete standstill, the cars enormous power is made visible by its impressive
mid-engine, elevated majestically beneath the chassis. Simultaneously, the Veyrons bold
proportions, well-balanced surfaces, and clear line structures give an impression of pure,
sleek elegance.
The design of the Veyron honors a great heritage without drifting off into retro style.
Every detail of the classic two-tone color scheme, a quote from the 1920s and 1930s, has
been carefully thought out, resulting in the typical Bugatti profile with the classic,
contrasting ellipsis the stylistic element used by Ettore Bugatti himself. The crest
line, which runs uninterrupted from the hood to the only 1.21-m-high roof, is a proud
homage to the Veyrons forebears. Thus, the Veyrons classic paintwork and harmonious
design connect this state-of-the-art super sports car to the glorious heritage of Bugatti
automobiles.
With its classic look, the large radiator grill adorned with the hand-enameled Bugatti
emblem represents the grandness of the Veyron. The sports cars distinctive front is
defined by the harmonious contrast of its broad headlights and majestic grill. The rear
end, 1.99 m wide, features the formidable retractable spoiler and generously designed
fenders. The Veyron perfectly fulfills the main design objective governing the
development of the new Bugatti: an uncompromising combination of highest elegance
and state-of-the-art technology.

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A birds eye view of the Veyron

Birthplace Of The Veyron

The Bugatti Veyron is masterfully manufactured in the new Atelier in Molsheim,
Alsace.

The new production facility is located near the former Bugatti headquarters at Chateau
St. Jean. It was built under the aegis of internationally renowned architect Gunter
Henn. Only a short distance away is the simply designed storage building that houses
the parts and spare parts supplied by top European manufacturers. The futuristic
Atelier workshop has little in common with the completely automated production
facilities of todays automotive industry. The modern, functional building is marked by
its elliptical layout, calling to mind the shape that Ettore Bugatti himself favored in his
designs so much so that it is epitomized in the company logo.
In front of the tall window faade that offers a beautiful view of the Vosges Mountains,
three workstations are set up on the bright, epoxy-coated floor. Eight carefully selected
and highly qualified employees assemble the Veyron piece by piece in this Spartan
environment. No more than one or two vehicles per week are produced in the Atelier,
each one requiring almost three weeks of careful assembly. The mechanics create the
Veyrons lightweight chassis; the formidable body is assembled; the 736 kW (1,001 HP)
engine, four-wheel drive, and brake system provide the cars basic functionality; the
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electronic control systems, convenience functions, and sound system disappear beneath
the impeccable surface made of the finest leather and uniformly gleaming aluminum
elements. For the customer, it is a special treat and unforgettable experience to witness
the creation of his very own Veyron here at Molsheim, the venerable birthplace of
Bugatti.

How the Bugatti Veyron Works?

How would you define the most amazing production car in the
world? Would it be:

The car with the most horsepower?

The car with the fastest top speed and acceleration?

The most expensive car?

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At the moment, the Bugatti Veyron appears to have it all:

A W-16 engine that can produce 1,001 horsepower

A top speed of 250+ mph (400+ kph)

A zero-to-60 time of three seconds

A zero-to-180 time of 14 seconds

A price tag somewhere in the $1.2 million range.

TECHNICAL

SPECIFICATIONS

Gearbox: 7 Gear DSG, fuel consumption in town: 41.9l/100km, fuel consumption out of
town: 15.6l/100km, fuel consumption combined: 24.9l/100km, CO2 emission combined:
596g/km, Efficiency Class: G
Annual tax for this vehicle 1132
Energy costs at a mileage of 20,000 km:
Fuel costs (Super Plus) at a fuel price of 1.624 EUR/billing unit 8087.52
Created on: 11/30/2011

In this article, we will take an in-depth look at this amazing automobile and see
how it is possible to fit so much performance into a single machine. It all starts
with the engine...

Veyron Engine: Heart of the Beast

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The Bugatti Veyron is a car built around an engine. Essentially, Bugatti made the
decision to blow the doors off the supercar world by creating a 1,000-horsepower engine.
Everything else follows from that resolution.
So let's start with the engine. How would you begin the design process for an engine this
powerful? If you have read How Car Engines Work, you know that if you want to create a
1,000-horsepower engine, it has to be able to burn enough gasoline to generate 1,000
horsepower. That works out to about 1.33 gallons (5 liters) of gasoline per minute.
We need a 16-liter engine to burn 1.33 gallons of gas per minute. That actually makes
sense -- the engine in the Dodge Viper is 8.0 liters in displacement and produces 500 hp.
But there's a problem: A 16-liter V-8 engine would be very large. And the pistons would
be massive, so there would be no way it could turn at 6,000 rotations per minute (rpm).
It might turn at a maximum of 2,000 rpm, meaning that you would need an immense
48-liter engine to generate 1,000 hp. Clearly an engine that big is impossible in a
passenger car.
So how did Bugatti fit 1,000 horsepower into a passenger car? Let's find out.

The Bugatti Veyron's 16-cylinder monster engine produces 1,001 horsepower for a top speed of more than 250
mph. And it's a passenger car.

Creating the Engine

Bugatti did two things to create a compact engine capable of producing 1,000 hp. The
first and most obvious thing isturbocharging.
If you have read How Turbochargers Work, you know that one easy way to make an
engine more powerful without making the engine bigger is to stuff more air into the
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cylinders on each intake stroke. Turbochargers do that. A turbo pressurizes the air
coming into the cylinder so the cylinder can hold more air.
If you stuff twice as much air in each cylinder, you can burn twice as much gasoline. In
reality, it's not quite a perfect ratio like that, but you get the idea. The Bugatti uses a
maximum turbo boost of 18 PSI to double the output power of its engine.

Engine and air snorkels

Therefore, turbocharging allows Bugatti to cut the size of the engine from 16 liters back
down to a more manageable 8 liters.
To

generate

that

much

air

pressure,

the

Bugatti

requires four

separate

turbochargers arranged around the engine.

The second thing Bugatti engineers did, both to keep the RPM redline high and to lower
lag time when you press the accelerator, was to double the number of cylinders. The
Bugatti has a very rare 16-cylinder engine.
There are two easy ways to create a 16-cylinder engine.

One way would be to put two V-8 engines in-line with each other. You connect the
output shaft of the two V-8s together.

Another would be to put two in-line 8-cylinder engines beside one another.
The latter technique is, in fact, the way Bugatti created its first 16-cylinder cars in the
early 20th century.
For the Veyron, Bugatti chose a much more challenging path. Essentially, Bugatti
merged two V-8 engines onto one another, and then let both of them share the same
crankshaft. This configuration creates the W-16 engine found in the Veyron. The two
V's create a W. You can see exactly how this looks in a set of beautiful videos available on
the Bugatti Web site (click here for instructions on how to access the videos).

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Then, Bugatti started piling on features to make the engine even better...

Special Features
The special features of the Bugatti W-16 engine are amazing. For example:

The engine has four valves per cylinder, for a total of 64 valves.

It has a dry sump lubrication system borrowed from Formula 1 race cars, along
with an intricate internal oil path to ensure proper lubrication and cooling within the 16
cylinders.

It has electronically controlled, continuously variable cam timing to create

optimal performance at different engine rpm settings.

It has a massive radiator to deal with all of the waste heat that burning 1.33
gallons of gasoline per minute can generate.
Everything about the engine is superlative.
And it is remarkably compact. It measures just 710 mm (27 inches) long, 889 mm (35
inches) wide and 730 mm (28.7 inches) high. This is the beauty of Bugatti's W-16
approach -- the engineers managed to fit 1,000 hp into a reasonably sized package.
In order to harness all of this horsepower and torque, you need an amazing
transmission...
The Transmission
The transmission is unique, in particular because it has to harness about twice as much
torque as any previous sports-car transmission. It has:

Seven gears

A dual clutch system

Sequential shifting

A paddle-driven, computer-controlled shifting system

This computer-controlled system is identical to the sort of system found in a Formula 1
car or a Champ car. There is no clutch pedal or shift lever for the driver to operate -the computer controls the clutch disks as well as the actual shifting. The computer is
able to shift gears in 0.2 seconds.
See Audi: Uninterrupted Power: Technical Details for more information on dual-clutch
systems.
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It would be almost impossible for all of the torque available from the W-16 engine to flow
out to just two wheels without constant wheel-spin. Therefore, the Veyron has fulltime all-wheel drive. By applying the engine's power to all four wheels through a
computer-controlled traction-control system, the car is able to harness all of the engine's
horsepower, even at full acceleration.

Chiselling Out The Body

According to one of the Veyron's designers, the biggest challenge in creating the Veyron
was the aerodynamics. How do you keep a 250-mph passenger car on the road?

An F-1 car or a Champ car can travel at 250 mph or more, but they have a uniquely
designed body, a single driver lying in a reclining position, just an inch or so of ground
clearance and an aero-package made up of large wings to generate massive downforce.
The Bugatti, on the other hand, is trying to look like a normal car and seat two
passengers.
The Veyron's dimensions help to some extent. The car is 79 inches (200 cm) wide, 176
inches (447 cm) long and only 48 inches (122 cm) high. Keep in mind that a Hummer 2 is
81.2 inches wide. The Bugatti is extremely wide for its height.

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The Bugatti Veyron's tail wing creates downforce at high speeds. Engine and air snorkels

The Bugatti Veyron's tail wing creates downforce at high speeds. Engine and air snorkels

The underside of the Veyron, like an F-1 car, is streamlined and venturi-shaped
to increase downforce. There is also a wing in the back of the Veyron (see below)
that extends automatically at high speed to increase downforce and keep the car
glued to the road. According to Popular Science: Hypercar, "With the moving tail
spoiler we've got enough downforce now, about 100 kg (221 pounds) at the rear
and 80 kg (177 pounds) at the front at top speed."
If you look at the above photo, you'll notice two snorkel-like devices, one on either
side of the engine, on the roof of the car. The Veyron uses these to manage
airflow. The Veyron has three reasons for managing airflow:

At maximum power, the engine is consuming 45,000 liters of air per

minute.

At maximum power, the engine is burning 1.33 gallons of gasoline per

minute and needs to dissipate all of that heat through its radiators.
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When stopping, the brakes need to dissipate heat ?- especially important

when rapidly accelerating and braking on twisty road courses .

You can see how the Veyron handles these requirements in the photo below. The engine
of the Veryon sits behind the driver, so roof-mounted snorkels, the rear-deck vents and
side-mounted scoops bring air to the engine and rear brakes.
The size of the engine and transmission, along with the four-wheel-drive system and the
four drive shafts, along with the opulence of the passenger compartment (discussed in
the next section) and the car's oversized dimensions, all add weight. Even though the
body is sculpted in carbon fiber to minimize its mass, the car weighs in at about 4,300
pounds (1,950 kg). For comparison, a Dodge Viper weighs about 1,000 pounds (454 kg)

less

The Tires and Interior

Even the tires for the Veyron are unique. They're specially designed by Michelin to
handle the stress of driving at 250 mph. The tires need to be sticky like a race car's and
able to handle 1.3 G's on the skidpad. However, they also need to last longer than the 70
or so miles of a typical race tire.
Michelin therefore created completely new tires to handle the Veyron's unique
requirements. In the rear, the tires are 14.4 inches (36.6 cm) wide. Specifically, the tires
measure 245/690 R 520 A front and 365/710 R 540 A rear, where 245 and 365 are the
width in millimeters (9.5 and 14.4 inches respectively). The rims are 520 mm and 540
mm in diameter (approximately 20 inches). These tires, in other words, are massive -the rears are the widest ever produced for a passenger car.

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The tires use the Michelin PAX system. Their pressure is monitored automatically, and
they can run flat for approximately 125 miles (201 km) at 50 mph (80 kph). According to
Michelin, the run-flat detection system "plays an integral role in active safety in PAX
System. Its role is to inform you of a loss of pressure, either gradual or sudden." Once
warned of an air leak by the PAX system, you can reduce your speed and head toward a
tire repair center.
One advantage of the PAX system and its run-flat ability is that it eliminates the need
for a spare tire.

Photo courtesy Bugatti Automobiles S.A.S. Photo courtesy Bugatti Automobiles S.A.S.

The Interior
The Veyron seats two in lavish style. The interior is swathed almost completely in
leather -- the dash, seats, floor and sides are all leather. Only the instruments and a few
metal trim pieces interrupt the leather experience.

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The car also surrounds its occupants with every sort of electronic nicety, including a
remarkable stereo system, navigation system, etc.
Is all of this worth a million bucks? Who knows? But regardless, the Veyron represents a
remarkable technological achievement.
The Veyron is also likely to represent the far end of the automotive performance
spectrum for some time to come. To create a car much faster will require adding even
more weight, and delivering even more power to the wheels. The added weight means
diminishing returns in the power-to-weight domain. Additional power means more
wheelspin.
Look at a Champ car and consider how radical its appearance is compared to a
passenger car. Consider also that a Champ car does not go much faster than the Veyron.
The Veyron probably approaches the outer limits of the passenger car envelope, and we
are unlikely to see much beyond the Veyron in terms of performance.
This is, in other words, as good as it gets.

Conclusion : Masterful Technology

With its 16-cylinder four-wheel drive, the Bugatti Veyron may well be
the

most

sophisticated

production

vehicle

of

all

times.

Most of the components tucked beneath its hood are ingenious innovations that
were formerly only deemed possible by visionaries like Ferdinand Pich.
Boasting a maximum speed of more than 400 km per hour, the Veyron is
unmatched in the super sports category. It offers a total of 736 kW (1,001 HP),
and its ample power reserves even at high speeds are the fabric of dreams for
luxury-class limousines: for a constant speed of 250 km/h, the Veyron only needs
270-280 HP. This means that the seven-gear clutch transmission works with a
torque of up to 1,250 Newton meters. The Electronic Stability Program ensures
the necessary flexibility and maneuverability at any speed. The Veyron reaches
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velocities that would literally lift the car off the ground if it werent for its
ingenious aerodynamics, which keeps it firmly on the road even at full speed.
Adjusting the back spoiler, reducing ground clearance, opening and closing the
lids it all adds to the perfect balance between propulsion and downforce. Such a
super sports car may not seem to be brought to a halt easily, but the Veyrons
ceramic brakes slow it down faster than it can accelerate. While it takes this
exceptional car only 2.5 seconds to go from 0 to 100 km/h, it needs even less time
a mere 2.3 seconds to come to a standstill from 100 (reference point). To
reduce the risk of injuries in accidents, Bugatti had a Formula 1 safety concept
adapted for the Veyron. All these technical details combine to make the Veyron a
truly exceptional super sports car.

...................................................................

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