reliability innovation performance excellence

Company Overview
Cosworth leverages its successful motor sport pedigree, performance technology expertise and globally recognised brand to provide high quality engineered solutions for a growing customer base across diverse industries. The companys head ofce in

Northampton is home to leading edge engineering, world class manufacturing and comprehensive test facilities. Our business is geared to deliver smart solutions and exceptional service to customers around the world. Over the years we have developed in-depth knowledge of engines, engine components and engine management systems. This has been successfully used to supply engines to some of the most successful Formula One teams and vehicle manufacturers. Our unprecedented success in the performance market has fuelled customer demand from diverse market sectors. In addition to the traditional markets, Cosworth is engaged in designing and developing, engines and components for marine, rail, aerospace and power generation applications. In North America we support our customer base from Cosworths sister facility in Torrance, California. A rigorous and comprehensive product quality assurance policy is implemented across our business. Quality engineering is embedded in processes, procedures and team ethic; we operate under the recognised quality management system AS9100 and environmental management system ISO14001. Our dedicated workforce focus on providing high quality products and solutions to meet ever demanding customer needs.
Cosworth USA - Torrance, California Cosworth UK - Northampton, England

smart solutions and exceptional service

AS/EN 9100
FM 22201

ISO 14001
EMS 87074

Our broad expertise includes: Software Hardware Electronic Systems Electrical Engineering Material Science Mechanical Engineering Manufacturing Process Development Systems Integration

Engineering
Cosworth provides cost effective, project managed, intelligent solutions for an array of engineering assignments. Our world renowned success in top ight racing programmes (including Formula One, World Rally Championship, Champ Car and IRL) together with our proven engineering capability in marine, road car and defence applications makes Cosworth a natural choice for customers with challenging requirements. All of our services and solutions can be customised to meet client needs and delivered through a single point of contact, enhancing customer relationship and return on investment. Our Design and Application Engineers are among the most experienced and highly skilled in the industry, utilising advanced techniques in areas such as Computer Aided Design and Finite Element Analysis. The in-house metallurgy lab and state-of-the-art test facilities complement our product development. With the expertise and resources of Cosworth supporting customer investment in new product or service development the possibilities are endless. We can improve the performance of existing products or create innovative new solutions giving our customers the vital competitive advantage to increase their market value and share. Our customer focused products and services enable our clients to competitively meet the demands of the marketplace, today and tomorrow.

giving our customers a competitive advantage

Aerospace
TOOLS CAD/CAM NX4, Vericut ENGINEERING SERVICES
Design Analysis Simulation Testing & Validation Manufacturing Product Lifecycle Management Software Development Electronics Material Development

Marine

Automotive

FEA Patran, Abaqus, Nastran CFD Star-CD

Power Generation

Aftermarket

1D GT Power Dynamic Analysis Multi-Body Dynamics Software & Proprietary Applications

Rail

Racing

Medical

Design and Development

Cosworth has unrivalled experience in both normally aspirated and forced induction high performance engine design and development. Projects range from modied production engines for niche markets through to the complete design, manufacture and development of Le Mans endurance engines. Whilst most recognised Cosworth products are clean sheet designs, our design and development services regularly optimise the power, durability, efciency and weight of clients existing engines, subassemblies and individual engine components, as well as other mechanical systems. The level of analysis applied is appropriate to the scale of each project and is complimented by the detailed knowledge of our experienced engineers.

Finite Element Analysis

Primarily used for structural analysis of components using Patran or CAE software with Abaqus and Nastran

Computer Aided Engineering

Software based analysis is a key element of Cosworths core skills. A variety of computational tools and techniques are used to allow Cosworths engineers to solve engineering problems for customers. Components are analysed and evaluated allowing virtual optimisation of new designs prior to manufacturing or testing, thus reducing lead times. Cosworth continually develops CAE methods to produce models that accurately represent real components in a range of applications.

solvers.

FEA allows an engineer to

understand the behaviour of a component under load, as well as the analysis of heat transfer, for large and small components including cylinder heads, crank cases and pistons. Combining FEA with CFD or 1D simulation enables very detailed analysis to be executed.

Programme Management
Cosworth has the expertise and infrastructure to successfully manage both large and small scale engineering projects. Projects range from an 80cc single cylinder heavy fuel engine for the UAV market through to complete engine development programmes for major automotive manufacturers. As part of our programme management work we have developed software tools for assigning serial numbers, tracking component life and managing engine specications.

1D Engine Simulation
Cosworth is a world leader in the creation, verication and development of engine simulation models to predict engine performance (including power output, efciency, cylinder pressures and heat transfer coefcients). The resulting output also delivers accurate predictions on ow, pressure and wave tuning effects in engine intake and exhaust systems. Our experience correlating and conrming models allows us to condently perform virtual tests in order to reduce costly and time consuming dynamometer tests.

Computational Fluid Dynamics

State of the art computers running STAR-CD software perform the millions of calculations required to simulate the interaction of uids through complex geometries. This allows a diverse range of uid ow problems to be analysed. Various types of uids can be simulated including air, coolants, fuels and oils in a variety of situations within an engine. CFD can be coupled with 1D engine simulation data to allow full simulation and optimisation of an engine intake and exhaust system.

Dynamic Analysis
The vibration of crankshafts, camshafts and various other valvetrain components can all be analysed using Multi-Body Dymamics software and proprietary applications. The results give a thorough understanding of the dynamic behaviour of systems within an engine. The vital data generated aids the elimination of torsional vibration problems and assists in the development of camshaft proles by predicting the dynamic behaviour of the valves.

Electronics
Cosworths considerable electronics expertise gathered over many years has seen us manufacture many bespoke electrical products in-house. Our products are used in numerous applications and vehicles from high performance road cars to World Rally and Formula One. We are able to offer a range of high quality prototype, small batch assembly, rework and test services, including: Wiring looms and loom cassettes Electromechanical sensors and actuators Semi-rigid and exible PCBs using through hole, surface mount and BGA components In addition we offer on-engine ignition system performance measurement and fault diagnosis as well as vibration and high temperature environmental testing.

Engine Testing
Initial engine design is only part of the journey to the nished product. Cosworths engine test facility houses ten fully instrumented dyno cells including two state of the art regenerative speed of dynamometers 24,000rpm. We rated are to 1,000kW and a maximum rated able to measure and analyse an array of engine performance and mechanical behaviour and can carry out performance, calibration and endurance testing on a wide range of engines. We can test many engine systems in isolation using bespoke test rigs including valvetrain, oil, water, fuel and ignition systems. We also offer a vibration measurement service the which specialises analysis in and measurement,

management of engine, vehicle and dyno torsional vibration.

Almost any type of naturally aspirated or forced induction engine can be tested for road, race and marine applications running on diesel, petrol or alcohol based fuels. To reduce the need for extensive eld testing the air presented to the engine can be altered for varying levels of temperature and humidity to simulate different operating conditions. Engines can be put through their paces under any type of endurance, calibration and performance testing. A wide range of data can be captured and analysed, providing the complete service necessary to optimise performance and meet design targets. The cells are highly congurable and our capability extends to testing complete engine and transmission powertrains as required.

Metallurgy
The Material Science department is an integral part of Cosworths engineering capability and contributes to the technological advancement of its products in all markets. We have extensive experience of determining root cause failure of components and assemblies manufactured from a wide range of materials. On request, our customers can take advantage of our rapid investigation service; over 90% of the failure analysis work is reported back to clients within 3 days. The Material Science department offers: Research and development into advanced materials to increase either component performance or durability. Failure analysis of components, with the option of recommendations to increase durability. Material selection advice for component designs. Thermal and mechanical processing development, evaluation and selection of components. Advice on surface treatments Value engineering to help the customer optimise cost

In addition to the design of engines and engine components Cosworth is also able to offer advice on enhancing the performance, durability, efciency and weight of existing engines, engine components and other mechanical systems. Our recommendations are made by highly experienced design and development engineers and backed up by a level of analysis appropriate to the scale of each project.

Capabilities:
Tensile Testing Fatigue Testing Rolling Contact Fatigue Wear/Friction Testing Electron Microscope with Chemical Analysis Non-destructive Fluorescent Dye and Magnetic Particle Flaw Detection

an analytical approach to solving problems

Aerospace & Defence

As a world leader in advanced engine and engineering technology, Cosworth combines state-of-the-art machining capabilities with highly experienced and focussed engineers to provide Total Solution capabilities to the aerospace and defence sectors. Cosworth is an AS9100 accredited provider of quality components and services with an established and expanding Aerospace and Defence customer base.

Cosworth the

continues

to of

embrace forging

motorsport

heritage

partnerships with like minded companies and organisations. to providing Its commitment excellence engineering

and innovative solutions is backed by sizeable capital investments to support long term strategies.

In addition to robust supply chain and logistics management Cosworth excels in specialist aerospace component manufacture, material science and production engineering processes for Reciprocating Engine components, complex Prismatic and Cylindrical products and Specialist Engine production.

Prototyping Small, Medium, High Volume Production Working in Partnership

Today Cosworth provides three categories of products in the aerospace market:

Reciprocating engine components our piston, camshaft, crankshaft, cylinder head, crankcase and other related products are employed in the general aviation industry by a number of original equipment manufacturers. Complex Prismatic and Cylindrical products global OEMs and major Tier 1 players source Cosworth components manufactured from billet, forgings and castings from most materials. HFE Engines to date the Cosworth AE-1 engine is the only true compression diesel engine designed for UAV applications that has been ight tested.

Quality & Service

Accreditations: AS9100B ISO9001:2000 ISO14001:2004 NDT NADCAP ISO17025 FAA Forging (Quality Management System) (Quality Management System) (Environmental Management System) (Non-Destructive Testing) (Competence of Testing and Calibration Laboratories) (Piston Production)

AS/EN 9100
FM 22201

Applications (typical)
Internal Combustion Engine Development & Analysis Complex Cylindrical & Prismatic Components utilising CAE, CAD/CAM, FEA with Integrated CMM Reverse Engineering Production Engineering Rapid Prototyping Supply Chain Management Precision Casting Die-pot forging Volume production of Aerospace Pistons from forging, casting or billet Value engineering

ISO 14001
EMS 87074

Facilities & Equipment

Machining Centres: 3, 4 and 5 axis vertical milling (multiple sets) Turning, grinding, jig boring, lapping, honing & polishing centres Aqueous & ultrasonic wash Assembly & pressure test areas Vibratory polishing 4 quadrant transient dynamometer Motored & instrumented test facilities (fuel, air, oil, hydraulic.etc)

Component and engine test facilities:

Materials laboratory
Tensile Testing Fatigue Testing Rolling Contact Fatigue Wear/Friction Testing Scanning Electron Microscope with Chemical Analysis Non-destructive Fluorescent Dye and Magnetic Particle Flaw Detection

AE-1 Heavy Fuel Engine

True diesel compression ignition Scalable Design Philosophy (3hp 20hp typical) High power density Low vibration levels Low fuel consumption Low maintenance rugged package Multiple fuels: Automotive diesel, JP5, JP8, DF1, DF2, F44 AVCAT, F76 DIESO

Engine Research & Design

Cosworth offers research, design, development, production and test for Spark Ignition and Compression Ignition cycles plus forced induction engines based on 50 years experience of through life management of high performance internal combustion engines, engine components and systems. Engine congurations range from single cylinder engines through to high performance road and racing V12 engines for demanding applications including Formula 1.

Enterprise Business Systems

Cosworth operates under the fully integrated business management underpinned by SAP that allows seamless operation with similarly provisioned customers and ensures the highest standards of business operation and control. SAP is fully integrated with the CAD/CAM manufacturing system. Vericut is also employed to reduce machining cost and risk, and improve yields. Cosworths computer aided design workow is compatible with all major drawing solid model formats including NX, Catia, Solidworks, ProE, Inventor, Step, and IGES.

Pi Research
Pi Research is a sister company to Cosworth, recognised throughout industry as a market leader in high performance electronics. Pi Research specialises in providing data acquisition, data analysis and control capabilities in highly reliable, compact, rugged designs able to withstand arduous environmental conditions. Offering experience of UAVbased data acquisition, on-board data reduction and real time telemetry, combined with its lightweight compact designs, Pi Research can provide technologies that maximise UAV payload deployment and performance. Pi Research provides turnkey solutions as well as design, manufacturing and support capabilities. Pi Research market sectors include: Professional Motorsport Marine Sailing and Powerboats Specialist Vehicles Aerospace Media Data for Sports and Entertainment

Existing Group Customers Contact details:

Cosworth Limited St James Mill Road Northampton NN5 5RA United Kingdom Tel: Fax: +44 (0)1604 598300 +44 (0)1604 598301 Cosworth LLC 3031 Fujita Street Torrance California, 90505 USA Tel: Fax: +1 310 534 1390 +1 310 534 2631

Email: clsales@cosworth.com Web: www.cosworth.com

Email: sales@cosworth.com Web: www.cosworthusa.com

Pi Research Brookeld Motorsports Centre Twentypence Road, Cottenham Cambridge, CB24 8PS United Kingdom Tel: Fax: +44 (0)1954 253600 +44 (0)1954 253601

Pi Research LLC 8250 Haverstick Suite #275 Indianapolis, IN46240 USA Tel: Fax: +1 (317) 808-3800 +1 (317) 259-0137

Email: enquiries@piresearch.co.uk Web: www.piresearch.com

Email: enquiries@piresearch.co.uk Web: www.piresearch.com

Aftermarket
Upgrading vehicles and tuning engines is a growing phenomena around the world and Cosworth is uniquely positioned within the aftermarket sector to provide customers with performance engine and upgrade components for a wide range of vehicles. Cosworths racing experience has been applied to its entire aftermarket product range and each family of products goes through rigorous trials to meet strict standards for quality and performance. Cosworth aftermarket products are available from authorised distributors in many countries and signicant gains in performance and durability can be achieved upon installation. tuned vehicles are Cosworth rave receiving

reviews from magazines, and frequently winning races and time attacks around the world.

extreme performance and durability

Our product range includes: Pistons Connecting Rods Block assemblies Crankshafts Camshafts Gaskets Air Filters Valve train components

Manufacturing
Our customer service driven manufacturing facility is organised as highly responsive market focused cells providing bespoke product needs. By utilising high integrity materials, employing meticulous process control, adherence to quality systems embedded throughout the business, Cosworth delivers customer product requirements. To reduce lead time and deliver right rst time products, fully integrated CAD-CAM and Vericut machine simulation is employed using all major CAD solid model formats. From one off to large batch requirements, our highly skilled & experienced workforce is used to providing precision engineered products in short lead times.

Materials include: Aluminium Titanium Magnesium Steel (including hardened steel)

Our manufacturing processes focus on: Reducing setup time Reducing manufacturing cycle time Minimising handling lights out manufacture Complete value chain management

leading edge technology for complex manufacturing

Operating under ISO9001 and AS9100, quality systems and procedures are embedded in every aspect of our culture and manufacturing processes. Our quality management includes: off line CMM programming from CAD master model using PCDMIS Full geometric, dimensional and form checking Root cause analysis on non-conformance Recorded and traceable inspection data Integrated CMM Full gauge management system Machine tool probing SPS data collection & analysis Materials analysis laboratory
AS/EN 9100
FM 22201

Our manufacturing facility:

ISO 14001
EMS 87074

3600m2 Floor Area Over 100 machine tools including 3,4 & 5 axis machining centres. CNC milling, turning, grinding & honing Dedicated piston line Integrated DNC computer network to control all data to and from the shop oor. Team based product centres

Pistons
Considering the environment pistons exist in with constant directional changes, massive acceleration and deceleration forces, enormous pressure and temperature, the need for performance and reliability is vitally important. Developed over 50 years in motorsport, our high quality pistons are manufactured to world-class standards to meet customer requirement. Cosworth has the expertise to design, develop and manufacture pistons for a broad range of petrol and diesel engines. We specialise in supplying pistons for engines used in motorsport, performance cars, aviation, commercial vehicles, rail traction, power generation and marine. applications. Our product range covers high and medium speed

piston performance and reliability

Cosworth appreciates todays market requirements, not only for increased power output but also maximum economy and service life with minimum emissions. Our products are designed using the latest parametric modelling technology, and designs are validated using Finite Element Analysis for stress distribution patterns. Flexibility is our watch word in

manufacturing, offering both small and high volume batch sizes.

Features/Capabilities: Diameter range: 40mm to 200mm Forged, cast and billet materials Aluminium grades - 2618, 4023 and proprietary CA009 Aln inserts Composite pistons - steel crown and forged aluminium skirt Variety of coatings Cooling galleries 3D proles Gudgeon pin hole proles Bowl proles Ring groove customisation

Cosworth Limited St James Mill Road Northampton NN5 5RA United Kingdom Tel: Fax: +44 (0)1604 598300 +44 (0)1604 598301

Cosworth LLC 3031 Fujita Street Torrance California, 90505 USA Tel: + Fax: 1 310 534 1390 +1 310 534 2631

Email: clsales@cosworth.com Web: w ww.cosworth.com

Email: sales@cosworth.com Web: w ww.cosworthusa.com

Pi Research Twentypence Road, Cottenham Cambridge, CB24 8PS United Kingdom Tel: Fax:
AS/EN 9100
FM 22201

Pi Research LLC 8250 Haverstick Suite #275 Indianapolis, IN46240 USA Tel: + Fax: 1 (317) 808-3800 +1 (317) 259-0137

+44 (0)1954 253600 +44 (0)1954 253601

Email: enquiries@piresearch.co.uk
ISO 14001
EMS 87074

Email: enquiries@piresearch.co.uk Web: w ww.piresearch.com

Web: w ww.piresearch.com