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Build variation and tolerance stack up are unavoidable in the vehicle manufacturing process, not only for individual components and assemblies but also for the vehicle at large. Deviations across several components, each within tolerance limits, could ultimately have a significant effect on vehicle aerodynamic performance. The objective of this study is to quantify the impact of several such build variations on vehicle drag. A Lattice-Boltzmann-based simulation method was used in conjunction with design of experiments to construct a Kriging response surface interpolation model to efficiently characterize the impact of 17 different body and chassis build variations on the aerodynamic drag of a VNL 780 tractor trailer at a nonzero yaw angle. The top three parameters with greatest aerodynamic impact were then evaluated at the opposite symmetric yaw angle to understand the impact of build variation on vehicle asymmetry.

Air flow in the underhood area is the primary source of engine cooling. A quick look at the vehicle underhood reveals exceptionally complex geometry. In addition to the engine, there are fans, radiator, condenser, other heat exchangers and components. The air flow needs to have adequate access to all relevant parts that require cooling. Due to complex geometry, the task to ensure sufficient air cooling is not a simple one. The air flow entering from the front grille is affected by many components on its path through the underhood. Even small geometry details affect the flow direction and can easily cause recirculation regions which reduce the cooling efficiency. Therefore, air cooling flow analysis requires detailed treatment of the underhood geometry and at the same time accurate air flow modeling. Recent advances in the lattice-Boltzmann equation (LBE) modeling are allowing both.