Cosworth Brochure 2008

reliability

innovation

performance

excellence

Company Overview

Our broad expertise includes:

Software• Hardware• Electronic Systems• Electrical Engineering• Material Science• Mechanical Engineering• Manufacturing Process • DevelopmentSystems Integration•

“smart solutions andexceptional service”

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 company’s head offi ce 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 Cosworth’s 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 UK - Northampton, England

Cosworth USA - Torrance, California

AS/EN 9100FM 22201

ISO 14001EMS 87074

Cosworth provides cost effective, project managed, intelligent solutions for an array of

engineering assignments. Our world renowned success in top fl 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.

Engineering

“giving our customersa competitive advantage”

frontback

In addition to the design of engines

and engine components Cosworth is

also able to offer advice on enhancing

the performance, durability, effi ciency

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.

Metallurgy

The Material Science department is an integral part of Cosworth’s 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•

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

“an analytical approachto solving problems”

TOOLS

CAD/CAMNX4, Vericut

FEAPatran, Abaqus, Nastran

CFDStar-CD

1DGT Power

Dynamic AnalysisMulti-Body Dynamics Software

& Proprietary Applications

ENGINEERING SERVICESDesign

Analysis

Simulation

Testing & Validation

Manufacturing

Product Lifecycle Management

Software Development

Electronics

Material Development

Aerospace Marine

Racing Medical

AutomotivePowerGeneration

Aftermarket Rail

Design and Development

Cosworth has unrivalled experience in both normally aspirated and forced induction high

performance engine design and development. Projects range from modifi ed 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, effi ciency 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.

Engine Testing

Initial engine design is only part of

the journey to the fi nished product.

Cosworth’s engine test facility

houses ten fully instrumented dyno

cells including two state of the art

regenerative dynamometers rated

to 1,000kW and a maximum rated

speed of 24,000rpm. We are

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 which specialises in

the measurement, analysis and

management of engine, vehicle and

dyno torsional vibration.

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 specifi cations.

Electronics

Cosworth’s 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 fl exible PCBs using through hole, surface mount and BGA • components

inside rightinside left

Computer Aided Engineering

Software based analysis is a key element of Cosworth’s core skills. A variety of

computational tools and techniques are used to allow Cosworth’s 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.

Computational Fluid Dynamics

State of the art computers running

STAR-CD software perform the millions

of calculations required to simulate the

interaction of fl uids through complex

geometries. This allows a diverse range

of fl uid fl ow problems to be analysed.

Various types of fl 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.

Finite Element Analysis

Primarily used for structural analysis

of components using Patran or CAE

software with Abaqus and Nastran

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.

1D Engine Simulation

Cosworth is a world leader in the

creation, verifi cation and development

of engine simulation models to predict

engine performance (including power

output, effi ciency, cylinder pressures and

heat transfer coeffi cients). The resulting

output also delivers accurate predictions

on fl ow, pressure and wave tuning

effects in engine intake and exhaust

systems. Our experience correlating

and confi rming models allows us to

confi dently perform ‘virtual’ tests in order

to reduce costly and time consuming

dynamometer tests.

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 profi les

by predicting the dynamic behaviour of

the valves.

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 fi 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 confi gurable and our capability extends to testing complete engine

and transmission powertrains as required.

In addition we offer on-engine ignition

system performance measurement and

fault diagnosis as well as vibration and

high temperature environmental testing.

Design and Development

Cosworth has unrivalled experience in both normally aspirated and forced induction high

performance engine design and development. Projects range from modifi ed 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, effi ciency 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.

Engine Testing

Initial engine design is only part of

the journey to the fi nished product.

Cosworth’s engine test facility

houses ten fully instrumented dyno

cells including two state of the art

regenerative dynamometers rated

to 1,000kW and a maximum rated

speed of 24,000rpm. We are

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 which specialises in

the measurement, analysis and

management of engine, vehicle and

dyno torsional vibration.

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 specifi cations.

Electronics

Cosworth’s 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 fl exible PCBs using through hole, surface mount and BGA • components


Computer Aided Engineering

Software based analysis is a key element of Cosworth’s core skills. A variety of

computational tools and techniques are used to allow Cosworth’s 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.

Computational Fluid Dynamics

State of the art computers running

STAR-CD software perform the millions

of calculations required to simulate the

interaction of fl uids through complex

geometries. This allows a diverse range

of fl uid fl ow problems to be analysed.

Various types of fl 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.

Finite Element Analysis

Primarily used for structural analysis

of components using Patran or CAE

software with Abaqus and Nastran

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.

1D Engine Simulation

Cosworth is a world leader in the

creation, verifi cation and development

of engine simulation models to predict

engine performance (including power

output, effi ciency, cylinder pressures and

heat transfer coeffi cients). The resulting

output also delivers accurate predictions

on fl ow, pressure and wave tuning

effects in engine intake and exhaust

systems. Our experience correlating

and confi rming models allows us to

confi dently perform ‘virtual’ tests in order

to reduce costly and time consuming

dynamometer tests.

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 profi les

by predicting the dynamic behaviour of

the valves.

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 fi 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 confi gurable and our capability extends to testing complete engine

and transmission powertrains as required.

In addition we offer on-engine ignition

system performance measurement and

fault diagnosis as well as vibration and

high temperature environmental testing.

Cosworth provides cost effective, project managed, intelligent solutions for an array of

engineering assignments. Our world renowned success in top fl 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.

Engineering

“giving our customersa competitive advantage”

frontback

In addition to the design of engines

and engine components Cosworth is

also able to offer advice on enhancing

the performance, durability, effi ciency

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.

Metallurgy

The Material Science department is an integral part of Cosworth’s 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•

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

“an analytical approachto solving problems”

TOOLS

CAD/CAMNX4, Vericut

FEAPatran, Abaqus, Nastran

CFDStar-CD

1DGT Power

Dynamic AnalysisMulti-Body Dynamics Software

& Proprietary Applications

ENGINEERING SERVICESDesign

Analysis

Simulation

Testing & Validation

Manufacturing

Product Lifecycle Management

Software Development

Electronics

Material Development

Aerospace Marine

Racing Medical

AutomotivePowerGeneration

Aftermarket Rail

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.

Aerospace & Defence

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 fl ight tested.

PrototypingSmall, Medium, High Volume ProductionWorking in Partnership

frontback

Cosworth LimitedSt James Mill Road

Northampton

NN5 5RA

United Kingdom

Tel: +44 (0)1604 598300

Fax: +44 (0)1604 598301

Email: [email protected]

Web: www.cosworth.com

Cosworth LLC3031 Fujita Street

Torrance

California, 90505

USA

Tel: +1 310 534 1390

Fax: +1 310 534 2631


Web: www.cosworthusa.com

Pi Research LLC8250 Haverstick

Suite #275

Indianapolis, IN46240

USA

Tel: +1 (317) 808-3800

Fax: +1 (317) 259-0137


Web: www.piresearch.com

Pi ResearchBrookfi eld Motorsports Centre

Twentypence Road, Cottenham

Cambridge, CB24 8PS

United Kingdom

Tel: +44 (0)1954 253600

Fax: +44 (0)1954 253601



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 UAV-

based 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

Cosworth continues to embrace

the motorsport heritage of forging

partnerships with like minded companies

and organisations. Its commitment

to providing engineering excellence

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.

Contact details:

AS/EN 9100FM 22201

ISO 14001EMS 87074

Quality & Service

Accreditations:

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

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•

Component and engine test facilities:

4 quadrant transient dynamometer• Motored & instrumented test facilities (fuel, air, oil, hydraulic.etc)•

Materials laboratoryTensile Testing• Fatigue Testing• Rolling Contact Fatigue• Wear/Friction Testing• Scanning Electron Microscope with • Chemical AnalysisNon-destructive Fluorescent • Dye and Magnetic Particle Flaw Detection

AE-1 Heavy Fuel EngineTrue 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

Applications (typical)Internal Combustion Engine Development & Analysis• Complex Cylindrical & Prismatic Components utilising CAE, CAD/CAM, FEA with • Integrated CMMReverse 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•


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 confi gurations 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. Cosworth’s computer aided design workfl ow is compatible with

all major drawing solid model formats including NX, Catia, Solidworks, ProE, Inventor,

Step, and IGES.

AS/EN 9100FM 22201

ISO 14001EMS 87074

Quality & Service

Accreditations:

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

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•

Component and engine test facilities:

4 quadrant transient dynamometer• Motored & instrumented test facilities (fuel, air, oil, hydraulic.etc)•

Materials laboratoryTensile Testing• Fatigue Testing• Rolling Contact Fatigue• Wear/Friction Testing• Scanning Electron Microscope with • Chemical AnalysisNon-destructive Fluorescent • Dye and Magnetic Particle Flaw Detection

AE-1 Heavy Fuel EngineTrue 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

Applications (typical)Internal Combustion Engine Development & Analysis• Complex Cylindrical & Prismatic Components utilising CAE, CAD/CAM, FEA with • Integrated CMMReverse 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•


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 confi gurations 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. Cosworth’s computer aided design workfl ow is compatible with

all major drawing solid model formats including NX, Catia, Solidworks, ProE, Inventor,

Step, and IGES.

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.

Aerospace & Defence

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 fl ight tested.

PrototypingSmall, Medium, High Volume ProductionWorking in Partnership

frontback


Northampton

NN5 5RA

United Kingdom

Tel: +44 (0)1604 598300

Fax: +44 (0)1604 598301


Web: www.cosworth.com


Torrance

California, 90505

USA

Tel: +1 310 534 1390

Fax: +1 310 534 2631


Web: www.cosworthusa.com


Suite #275


USA

Tel: +1 (317) 808-3800

Fax: +1 (317) 259-0137



Pi ResearchBrookfi eld Motorsports Centre


Cambridge, CB24 8PS

United Kingdom

Tel: +44 (0)1954 253600

Fax: +44 (0)1954 253601



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 UAV-

based 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

Cosworth continues to embrace

the motorsport heritage of forging

partnerships with like minded companies

and organisations. Its commitment

to providing engineering excellence

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.

Contact details:

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. Cosworth’s

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 signifi cant gains

in performance and durability can be

achieved upon installation. Cosworth

tuned vehicles are receiving rave

reviews from magazines, and frequently

winning races and time attacks around

the world.

“extreme performanceand durability”

Our product range includes:

Pistons• Connecting Rods• Block assemblies• Crankshafts• Camshafts• Gaskets• Air Filters• Valve train components•

Manufacturing

“leading edge technology forcomplex 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 fi 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.

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 •

Our manufacturing processes focus on:

Reducing setup time • Reducing manufacturing cycle time • Minimising handling – lights out manufacture • Complete value chain management•

Materials include:

Aluminium• Titanium• Magnesium• Steel (including hardened steel)•

Our manufacturing facility:

3600m• 2 Floor Area Over 100 machine tools including • 3,4 & 5 axis machining centres.CNC milling, turning, grinding & • honingDedicated piston line• Integrated DNC computer network • to control all data to and from the shop fl oor. Team based product centres •

AS/EN 9100FM 22201

ISO 14001EMS 87074

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. Our product range covers high and medium speed

applications.

Cosworth appreciates today’s 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 • 200mmForged, cast and billet materials• Aluminium grades - 2618, 4023 • and proprietary “CA009”Alfi n inserts• Composite pistons - steel crown • and forged aluminium skirtVariety of coatings• Cooling galleries• 3D profi les• Gudgeon pin hole profi les• Bowl profi les• Ring groove customisation•

“piston performance and reliability”

AS/EN 9100FM 22201

ISO 14001EMS 87074


Northampton

NN5 5RA

United Kingdom

Tel: +44 (0)1604 598300

Fax: +44 (0)1604 598301

Email: c [email protected]

Web: w ww.cosworth.com


Torrance

California, 90505

USA

Tel: + 1 310 534 1390

Fax: +1 310 534 2631


Web: w ww.cosworthusa.com

Pi Research


Cambridge, CB24 8PS

United Kingdom

Tel: +44 (0)1954 253600

Fax: +44 (0)1954 253601


Web: w ww.piresearch.com


Suite #275


USA

Tel: + 1 (317) 808-3800

Fax: +1 (317) 259-0137


Web: w ww.piresearch.com

Cosworth Brochure 2008

Documents

destructive

in46240 usa

quality management

finite element

reciprocating

pi research

90505 usa

power generation