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Presented are results from numerical investigations of buoyancy driven flow in a simplified representation of an engine bay. A main motivation for this study is the necessity for a valid correlation of results from numerical methods and procedures with physical measurements in order to evaluate the accuracy and feasibility of the available numerical tools for prediction of natural convection. This analysis is based on previously performed PIV and temperature measurements in a controlled physical setup, which reproduced thermal soak conditions in the engine compartment as they occur for a vehicle parked in a quiescent ambient after sustaining high thermal loads. Thermal soak is an important phenomenon in the engine bay primarily driven by natural convection and radiation after there had been a high power demand on the engine. With the cooling fan turned off and in quiescent environment, buoyancy driven convection and radiation are the dominating modes of heat transfer.

The aerodynamic drag, fuel consumption and hence CO2 emissions, of a road vehicle depend strongly on its flow structures and the pressure drag generated. The rear end flow which is an area of complex three-dimensional flow structures, contributes to the wake development and the overall aerodynamic performance of the vehicle. This paper seeks to provide improved insight into this flow region to better inform future drag reduction strategies. Using experimental and numerical techniques, two vehicle shapes have been studied; a 30% scale model of a Volvo S60 representing a 2003MY vehicle and a full scale 2010MY S60. First the surface topology of the rear end (rear window and trunk deck) of both configurations is analysed, using paint to visualise the skin friction pattern. By means of critical points, the pattern is characterized and changes are identified studying the location and type of the occurring singularities.

This article presents Computational Fluid Dynamics (CFD) simulations fo one period of a louvered fin, for a crossflow compact finned heat exchanger, where the incoming airflow was inclined relative to its core. Four inclinations were investigated: 90°, which was when the air flowed perpendicular to the heat exchanger, 60°, 30° and 10° angles relative to the vertical plane. The study included three heat exchanger designs, where two of them had symmetrical louvered fins and a thickness of 19mm and 52mm. The third had a thickness of 19mm and had the louvers angled in one direction. All heat exchangers have been simulated when the airflow entered both from above and below relative to the horizontal plane. Simulations have also been carried out when the airflow entered from the side, illustrating the heat exchanger to be angled relative to the vertical axis. Two air speeds have been investigated for each configuration, where the results were compared to experimental data.

The current work investigates a method in 1D modeling of cooling systems including discretized cooling package with non-uniform boundary conditions. In a stacked cooling package the heat transfer through each heat exchanger depends on the mass flows and temperature fields. These are a result of complex three-dimensional phenomena, which take place in the under-hood and are highly non-uniform. A typical approach in 1D simulations is to assume these to be uniform, which reduces the authenticity of the simulation and calls for additional calibrations, normally done with input from test measurements. The presented work employs 3D CFD simulations of complete vehicle in STAR-CCM+ to perform a comprehensive study of mass-flow and thermal distribution over the inlet of the cooling package of a Volvo FM commercial vehicle in several steady-state operating points.

Nowadays, much focus for vehicle manufacturers is directed towards improving the energy efficiency of their products. The aerodynamic drag constitutes one major part of the total driving resistance for a vehicle travelling at higher speeds. In fact, above approximately 80km/h the aerodynamic drag is the dominating resistance acting on a truck. Hence the importance of reducing this resistance is apparent. Cooling drag is one part of the total aerodynamic drag, which arises from air flowing through the heat exchangers, and the irregular under-hood area. When using Computational Fluid Dynamics (CFD) in the development process it is of great importance to ensure that the methods used are accurately capturing the physics of the flow. This paper deals with comparative studies between CFD and wind-tunnel tests. In this paper, two comparative studies are presented.

There are a number of numerical and experimental studies of the aerodynamic performance of wheels that have been published. They show that wheels and wheel-housing flows are responsible for a substantial part of the total aerodynamic drag on passenger vehicles. Previous investigations have also shown that aerodynamic resistance moment acting on rotating wheels, sometimes referred to as ventilation resistance or ventilation torque is a significant contributor to the total aerodynamic resistance of the vehicle; therefore it should not be neglected when designing the wheel-housing area. This work presents a numerical study of the wheel ventilation resistance moment and factors that affect it, using computational fluid dynamics (CFD). It is demonstrated how pressure and shear forces acting on different rotating parts of the wheel affect the ventilation torque. It is also shown how a simple change of rim design can lead to a significant decrease in power consumption of the vehicle.

Automotive aerodynamics measurements and simulations now routinely use a moving ground and rotating wheels (MVG&RW), which is more representative of on-road conditions than the fixed ground-fixed wheel (FG&FW) alternative. This can be understood as a combination of three elements: (a) moving ground (MVG), (b) rotating front wheels (RWF) and (c) rotating rear wheels (RWR). The interaction of these elements with the flow field has been explored to date by mainly experimental means. This paper presents a mainly computational (CFD) investigation of the effect of RWF and RWR, in combination with MVG, on the flow field around a saloon vehicle. The influence of MVG&RW is presented both in terms of a combined change from a FG&FW baseline and the incremental effects seen by the addition of each element separately. For this vehicle, noticeable decrease in both drag and rear lift is shown when adding MVG&RW, whereas front lift shows little change.

This paper presents results and a Computational Fluid Dynamics (CFD) method for simulation of a detailed louvered fin for a multi-louvered compact heat-exchanger. The airflow was angled at 90°, +30° and −30° relative to the heat-exchanger to evaluate changes in static pressure drop and airflow characteristics. The investigation was based on three heat-exchangers with thicknesses of 52mm and two of 19mm. One period of a detailed louvered fin was simulated for two airflows for each heat-exchanger. The pressure drop data was thereafter compared to experimental data from a full-size heat-exchanger. From the pressure drop and the airflow characteristic results recommendations were made that those kinds of simulations could be defined as steady state, and with the kω-SST turbulence model. For the same heat-exchanger angle the airflow within the core was similar, with a turbulent characteristic behind it.

Reducing resistance forces all over the vehicle is the most sustainable way to reduce fuel consumption. Aerodynamic drag is the dominating resistance force at highway speeds, and the power required to overcome this force increases by the power three of speed. The exterior body and especially the under-body and rear-end geometry of a passenger car are significant contributors to the overall aerodynamic drag. To reduce the aerodynamic drag it is of great importance to have a good pressure recovery at the rear. Since pressure drag is the dominating aerodynamic drag force for a passenger vehicle, the drag force will be a measure of the difference between the pressure in front and at the rear. There is high stagnation pressure at the front which requires a base pressure as high as possible. The pressure will recover from the sides by a taper angle, from the top by the rear wind screen, and from the bottom, by a diffuser.

Wheel and underbody aerodynamics have become important topics in the search to reduce the aerodynamic drag of the heavy trucks. This study aims to investigate, experimentally as well as numerically, the local flow field around the wheels and in the wheel housing on a heavy truck; and how different approaches to modelling the wheel rotation in CFD influences the results. Emphasis is on effects due to ground simulation, and both moving ground and wheel rotation were requirements for this study. A 1:4-scale model of part of a heavy truck geometry has been developed. During the model design numerical simulations were used to optimise the shape, in order to replicate the flow field near the wheel of a complete truck. This was done by changing the flow angles of the incoming and exiting flows, and by keeping the mass flow rates in to, and out of, the wheel housing at the same ratios as in a reference full size vehicle.

Today CFD is an important tool for engineers in the automotive industry who model and simulate fluid flow. For the complex field of Underhood Thermal Management, CFD has become a very important tool to engineer the cooling airflow process in the engine bay of vehicles. To model the cooling airflow process accurately in CFD, it is of utmost importance to model all components in the cooling airflow path accurately. These components are the heat exchangers, fan and engine bay blockage effect. This paper presents CFD simulations together with correlating measurements of a cooling airflow system placed in a test rig. The system contains a heavy duty truck louvered fin radiator core, fan shroud, fan ring and fan. Behind the cooling module and fan, a 1D engine silhouette is placed to mimic the blockage done by a truck engine. Furthermore, a simple hood is mounted over the module to mimic the guiding of air done by the hood shape in an engine bay.

This investigation is a continuing analysis of the cooling performance and aerodynamic properties of a rear-mounted cooling module on a semi-generic commercial vehicle, which was carried out by Larsson, Löfdahl and Wiklund. In the previous study two designs of the cooling package installation were positioned behind the rear wheelhouse and the results were compared to a front-mounted cooling module. The investigation was mainly focused on a critical cooling situation occurring at lower vehicle speeds for a local distribution vehicle. The conclusion from the study was that the cooling performance for one of the rear-mounted installation was favorable compared to the front-mounted cooling package. This was mainly due to the low vehicle speed, the high fan speed and to fewer obstacles around the cooling module resulting in a lower system restriction within the installation.

The aim of the study was to investigate the cooling performance of two cooling package positions for distribution vehicles by using Computational Fluid Dynamics. The first cooling package was positioned in the front of the vehicle, behind the grill and the second position was at the rear of the vehicle. Each case was evaluated by its cooling performance for a critical driving situation and its aerodynamic drag at 90 km/h, where the largest challenge of an alternative position is the cooling air availability. The geometry used was a semi-generic commercial vehicle, based on a medium size distribution truck with a heat rejection value set to a fixed typical level at maximum power for a 13 litre Euro 6 diesel engine. The heat exchangers included in the study were the air conditioning condenser, the charge air cooler and the radiator. It was found that the main problem with the rear mounted cooling installation was the combination of the fan and the geometry after the fan.

The aim with this investigation was to study the aerodynamic properties of truck-trailer combinations of varying lengths. The aerodynamic properties of the combinations were evaluated in order to study similarities and differences in the flow field between different configurations. By the use of Computational Fluid Dynamics (CFD) six different types of truck-trailer combinations used for long hauling have been evaluated. The combinations have a total length varying between 10.10 m and 25.25 m and consist of either a tractor or rigid truck in combination with one or two cargo units. All of the combinations are commonly found on roads in Sweden and several other countries in Europe. The results from the simulations show that the aerodynamic properties differ significantly for the truck-trailer combinations. It was found that the longer vehicle combinations are much more sensitive to yaw conditions than the shorter combinations.

Efforts towards ever more energy efficient passenger cars have become one of the largest challenges of the automotive industry. This involves numerous different fields of engineering, and every finished model is always a compromise between different requirements. Passenger car aerodynamics is no exception; the shape of the exterior is often dictated by styling, engine bay region by packaging issues etcetera. Wheel design is also a compromise between different requirements such as aerodynamic drag and brake cooling, but as the wheels and wheel housings are responsible for up to a quarter of the overall aerodynamic drag on a modern passenger car, it is not surprising that efforts are put towards improving the wheel aerodynamics.

The most common fan model to use in commercial CFD software today is the Multiple Reference Frame (MRF) model. This is at least valid for automotive under hood applications. Within the industry, for this typical application, this model is commonly known to under predict performance. This under prediction has been documented by the authors' of this paper in SAE paper 2009-01-0178 and VTMS paper 2009-01-3067. Furthermore has this been documented by S.Moreau from Valeo in “Numerical and Experimental Investigation of Rotor-Stator Interaction in Automotive Engine Cooling Fan Systems”, ETC, 7th European Conference on Turbomachinery, 2007. In preceding papers a specific methodology of use has been documented and it has been shown that the MRF model under predicts performance for the airflow in a cooling system commonly with 14% in volumetric flow rate. This is for a system dominated by inertial effects.

The drag from the underbody, including wheels and wheel housing, constitutes a significant amount of the total aerodynamic drag of heavy vehicles. A correct simulation of the underbody boundary conditions, including rotating wheels and moving ground, has turned out to be of great importance in the minimising of the aerodynamic drag. In the current study several front wheel housing design parameters have been evaluated using Computational Fluid Dynamics (CFD). Design concepts, like enclosed inner wheel housings, underbody panel and wheel housing ventilation, were evaluated by flow analysis and comparison of the drag force contribution. It was shown that changes to the wheel housing geometry had an important impact on the local flow field and force distribution. The total drag of the vehicle decreased with reduced wheel housing volume and wheel housing ventilation can reduce the aerodynamic drag significantly provided it is designed properly.

A common fan model to use in automotive under hood simulations is the Multiple Reference Frame (MRF) model and within the industry, for this specific application, this model is well known to under predict performance. In this paper we have examined the possibilities of correcting this deficiency with a simple “speed correction”. This is done by testing and simulating a production fan in the Volvo Fan Test Rig for two operating speeds, 1200 rpm and 2400 rpm. Pressure rise, fan power and static efficiency are presented as functions of volumetric flow rate. The simulations verify that using the MRF model the common behavior of under predicting pressure rise and performance of the fan occur. In addition, this work shows that; although the MRF is not predicting fan performance correctly it constitutes a reliable fan modeling strategy.

In the 1955 Le Mans race the worst crash in motor racing history occurred and this accident would change the face of motor racing for decades. After the crash numerous investigations on the disaster were performed, and fifty years after some interesting books were launched on the subject. However, a number of key questions remain unsolved; and one open area is the influence of aerodynamics on the scenario, since the Mercedes-Benz 300 SLR involved in the crash was equipped with an air-brake and its influence on the accident is basically unknown. This work may be considered as a first attempt to establish CFD as a tool to aid in resolving aerodynamic aspects in motor sport accidents and in the present paper, CFD has been used to investigate the aerodynamics and estimate the drag and lift coefficients of the Mercedes-Benz 300 SLR used in the Le Mans race of 1955.

In this case study the cooling airflow of an existing open wheeled racecar has been improved with the use of Computational Fluid Dynamics. The race team in context had at several occasions experienced overheating of their racecar and was looking for ways to improve the cooling performance without changing the bodywork radically. As the car is used for autocross events on tight and twisty courses it spends most of a lap in yawed condition. Therefore, a novel approach was taken to model these yawed conditions with the numerical method. The simulation was based on the fully detailed race car. Through the study it was possible to locate problem areas, and hence, give indications to where the bodywork should be modified. With subtle changes to the bodywork the cooling performance of the car was significantly improved and the drag kept at the same level.