Momentum - October 2019 - 15

STUDENT
GENERATION
'Warrior of good'
Zuura is Sanskrit for "warrior of good"-a brave fighter who represents virtue
against all odds. Team Zuura's weapons are the sharp intellects of its team of 60,
putting their all into conceiving a car with merits of virtue and excellence so it
can succeed at Formula SAE competitions. The team has been participating
regularly in such competitions since 2014. Starting with their first car, the ZFR-01,
they have continuously improved their designs over the decades to finally create
the ZFR-06 in 2018.

The full vehicle assembly as depicted in Adams/car.
0.65

Angle, degree

0.55

Testing.toe_angle.left;testrig,wheel_travel.vertical_left

0.45
0.35
0.25
0.15

0.05
0.0
-0.05
-25.0 -20.0

The Zuura Formula Racing team from VIT Chennai, India.
-15.0

-10.0

-05.0

0.0

5.0

Length, mm

10.0

15.0

20.0

25.0

This kinematic analysis depicts toe change vs wheel travel.
to compensate for body roll without anti roll bar. By
optimization of the hardpoints in the geometry, we also
incorporated better camber and roll center control by
doing parallel wheel travel and opposite wheel travel
analysis. Toe change and bump steer were also reduced
during the analysis.
After improving kinematic parameters, the main
role before us was to improve the ride and handling
characteristics by performing dynamics simulation. We
performed some turning tests to help measure yaw,
pitch, roll, and lateral acceleration, and then did some
design changes to obtain our goals. The simulations also
helped in analyzing toe effect, which affects the cornering capability of the car. After doing dynamic analysis,
we were able to accurately predict the loads, which
helped us in designing the components with lowest mass
possible. We also exported dynamics loads to do FEA
and stress analysis of the components.
We found that stiffer springs help reduce yaw, pitch,
and roll moment. Softer springs have large yaw, pitch,
and roll rates. This study also led the team to decide to
incorporate some toe for improvement in yaw rate and
cornering capability. We found that stiffer springs help
the vehicle to turn faster during cornering.
We also performed flex analysis of the control arm
to study deformation, stress, and strain after dynamic
suspension analysis, as well as structural simulation to
optimize the strength-to-weight ratio of the ZFR-06's
suspension. The suspension needs to be as light as
possible, but it also needs to survive all the loads it could
experience on race day. Thus, the team simulated all of

MOMENTUM

At Formula Student Australasia 2017, the team secured 13th rank
internationally among IC cars and 20th overall. In the competition's Cost Event, it
placed 10th, and in Business Presentation it placed 7th. Zuura is also the only
Indian team to clear the technical inspection round twice consecutively in the
history of the competition.
The team plans to take its design to the next level with further iterations and
participate, and hopefully, win in many more competitions, both in India and
abroad. The team's latest creation, the ZFR-06, ranked seventh overall and won
the static and design events at FFS India 2018.

This dynamic analysis depicts yaw rate versus time.
the suspension's components using ANSYS Mechanical, which enabled
the team to save weight from the suspension's parts while maintaining
an appropriate factor of safety.

This article was written for MOMENTUM by Sudeep Kumar, a third-year
mechanical engineering student at VIT (Vellore Institute of Technology)
in India. As a vehicle dynamics student engineer at Zuura Formula Racing,
he headed the design report team that placed second at the design
competition FFS India 2018.

October 2019 15



Momentum - October 2019

Table of Contents for the Digital Edition of Momentum - October 2019

Momentum - October 2019
Contents
EDITORIAL
BRIEFS
STUDENT GENERATION
Getting a grip on costs
75 points
Major redesign
One-on-One – Kaitlyn Baron
It’s all about suspension simulation for Zuura Formula Racing
Engineering the future of two-stroke
Digital suspension keeps cabs stable
Motion sickness meets autonomous adaptable dynamics
SAE 101: Books
Miscellaneous news for SAE Student Members!
Dossier: Justin AndresMooi of Yanfeng Automotive Interiors
Momentum - October 2019 - Momentum - October 2019
Momentum - October 2019 - Cover2
Momentum - October 2019 - Contents
Momentum - October 2019 - EDITORIAL
Momentum - October 2019 - BRIEFS
Momentum - October 2019 - STUDENT GENERATION
Momentum - October 2019 - 5
Momentum - October 2019 - 6
Momentum - October 2019 - Getting a grip on costs
Momentum - October 2019 - 75 points
Momentum - October 2019 - 9
Momentum - October 2019 - Major redesign
Momentum - October 2019 - 11
Momentum - October 2019 - 12
Momentum - October 2019 - One-on-One – Kaitlyn Baron
Momentum - October 2019 - It’s all about suspension simulation for Zuura Formula Racing
Momentum - October 2019 - 15
Momentum - October 2019 - Engineering the future of two-stroke
Momentum - October 2019 - 17
Momentum - October 2019 - Digital suspension keeps cabs stable
Momentum - October 2019 - Motion sickness meets autonomous adaptable dynamics
Momentum - October 2019 - SAE 101: Books
Momentum - October 2019 - Miscellaneous news for SAE Student Members!
Momentum - October 2019 - Dossier: Justin AndresMooi of Yanfeng Automotive Interiors
Momentum - October 2019 - 23
Momentum - October 2019 - 24
Momentum - October 2019 - Cover3
Momentum - October 2019 - Cover4
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