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.
Since 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.
ARC 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.
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.
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.
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.
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.
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.
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.
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.
Velocity cut plot and pressure surface plot (on motorcycle and driver)
Solver – OpenFOAM
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.
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
Pressure Plot of Stock Miata
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.
Pressure Plot of Lowered Miata
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
Pressure Plot of Current Setup
Pressure Plot Under Rear Wing
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
Pressure Plot Improved Car
Pressure Plot Under Rear Wing
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!
Deadwater in the Center of the Wing