Category Archives: consulting

Midwest Tour

So I’ve been travelling the Midwest the past few days to visit some of our manufacturers.  First, I went to see our suspension parts being made.  They have a large facility with a lot of CNC 3 and 5 axis machines, lathes, mills, benders, water jet, and welding stations.  This is only about 1/3 of the whole shop floor.

IMG_8241

IMG_8242They can do just about anything you can think of

IMG_8239Being able to do MIL-spec work, they are certified in just about every material, which shows in the stock they have

IMG_8243I have been discussing with them the idea of building our radiators and oil coolers.  They showed me the Denso core we would end up using for the FR-S/BRZ/GT86.

IMG_8245Then I went to visit our in autoclave composite manufacturer.  The tool for our SEW V2

IMG_8317Their large autoclave is 10’x20′, and is one of the largest in the country.

IMG_8312They work with teams at the highest levels of racing in the US as can be seen here

IMG_8326Since they had a bunch of defense projects laying around, I wasn’t able to take more pictures due to security reasons.  Then, I got to catch up with some of my old college friends and was told they were going to a 7 post rig test at ARC, so I watched that as well.

20130516_144147ARC also has a wind tunnel testing facility, but the team I was visiting didn’t have any wind tunnel time booked, so I didn’t get to see that.  Because the body panels were off the car and the guts were exposed, I couldn’t get any pictures of the car on the rig.  Sorry.  It’s been a very enlightening last few days, but I can’t wait to get back home tomorrow.

New Partnerships

We believe computer simulation is only one side of the coin, real world testing is the other.  We are just as careful of selecting our testers as we are in designing our product.  We choose people that will really push our products to the limit and put them in the conditions they were designed for.

bestentrycorkscrewMRLS1_zpsf12b4f93

Robert Fuller, owner of Robispec, most well known for suspension setup, tuning and component development for Evos and STis, will aid us with development.  He actively competes in time attack and NASA time trials and has one of the fastest FR-Ses on the west coast.  He will be testing the full gamut of our suspension components customized to his specifications and providing us with feedback for further improvements.  To stay updated with Robi’s FR-S, please check his build thread here.

2013_scion_fr-s_r34_lt_22713_600

For those without race cars and that want to see its road-worthiness, Edmunds.com will be testing our control arm on their long-term test car.  Their goal is to create a pure dual-purpose car that is just as comfortable and livable as OEM, but outperforms it at autocrosses and track days.  They are very selective of their modifications and will be making small changes at a time to see how each modification affects the vehicle.  To stay updated with their long-term test car, you can check out their website here.

Aero Updates

After a few long nights of solving and troubleshooting, Paul was finally able to complete the splitter design for Team NLS/Pure Precision’s GTI.

splitter_referenceWith this setup, the aero balance is 51:49 front-to-rear.  The CFD says that the setup will also  make in excess of 650 lbs of downforce at 100 MPH.

We also have a Single Element Wing Version 2 ready for order.  The wing utilizes a pre-preg carbon skin, with a rod and spar core, to make it highly modular.  The wing span can be up to 72″ and mounting points can be located as desired.

 

New Partnership

Now that the paperwork has been finalized, we are happy to announce Hancha has partnered up with Team NLS for the One Lap of America.

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NSFW is running a Mk. V VW GTI.  The car makes about 500 whp, with a full sequential gearbox.  For Team NLS, Paul will be doing CFD analysis of their rear wing’s effectiveness as well as designing a front splitter to tune the aero balance.  Paul has started cleaning up the solid model from a model of the OEM car.

cad_beginning_model_cleaned_simplifiedSo all you southeast guys, keep an eye out for the car later this year!

Mazda Miata Consultation

The first cfd consultation of Hancha Group. A Mazda Miata that races in SCCA Solo and track days wants to know whether aerodynamic changes actually helped performance.  He also wants to look into other aerodynamic performance changes.

actualPictureActual Picture of Car

s_2_cfd_modelCFD Model (No front splitter and no wing)

meshQuality_2Mesh Quality on Surface

The first analysis is of a stock Miata at stock ride height.   This was just for shear curiosity and to compare to the rest of the runs.

cd = 0.36

cl = 0.27

s_1_pressure_plot_1

Pressure Plot of Stock Miata

s_1_velocity_plot_1

Velocity Plot of Stock Miata

The next analysis was of a stock Miata lowered to have a 4 in ride height.  This was how the looked before the additional aero.

cd = 0.41

cl = 0.08

The results were as expected.  Lowering a vehicle will increase the downforce by increasing the velocity below the vehicle.  This does however increase drag.  The aero balance did not change between the runs.

s_2_pressure_plot_1

Pressure Plot of Lowered Miata

s_2_velocity_plot_1

Velocity Plot of Lowered Miata

This is all for now….currently running the current setup on the car to compare to it to the lowered Miata.  Stay tuned for more on this project.

Update on 01.14.2013

This project has been done for a little while. I am just now getting to the finished results.  The project was successful.

The next analysis was on the current cars setup.  The current car has a front splitter and a dual element rear wing. This setup did increase drag, as expected because of the rear wing. The big benefit that can be seen is the coefficient of lift.  The Miata is now making downforce!  Good news since drag currently isn’t the big concern.

cd = 0.51

cl = -0.93

s_3_pressure_plot_1

Pressure Plot of Current Setup

s_3_pressure_plot_4

Pressure Plot Under Rear Wing

s_3_velocity_plot_1

Velocity Plot of Current Setup

To improve this setup, the Hancha Single Element Wing was used instead of the dual element wing.  Single element wings are better to use if you can meet the downforce required because they will have less drag.  Now if you cannot meet the downforce required, duel element wings would have to be used. This setup improved the performance by lowering drag and increasing the downforce.  This is a double win by increasing the efficiency!

cd = 0.48

cl = -1.00

s_5_pressure_plot_1

Pressure Plot Improved Car

s_5_pressure_plot_6

Pressure Plot Under Rear Wing

s_4_velocity_plot_1

Velocity Plot of Improved Car

This setup still isn’t perfect.  The wing is stalled in the center, which can be seen in the pressure plots of the car and the wing.  The picture below shows the deadwater behind this section of the wing.  Improvements are still in the process.  This car will be getting one of the prototype single element wings!

s_5_stream_3

Deadwater in the Center of the Wing