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Windscreen wipers are an integral component of the windscreen cleaning systems of most vehicles, trains, cars, trucks, boats and some planes. Wipers are used to clear rain, snow, and dirt from the windscreen pushing the water from the wiped surface. Under certain conditions however, water which has been driven to the edge of the windscreen by the wiper can be drawn back into the driver’s field of view by aerodynamic forces introduced by the wiper motion. This is wiper drawback, an undesirable phenomenon as the water which is drawn back on to the windscreen can reduce driver’s vision and makes the wiper less effective. The phenomena of wiper drawback can be tested for in climatic tunnels using sprayer systems to wet the windscreen. However, these tests require a bespoke test property or prototype vehicle, which means that the tests are done fairly late in the development of the vehicle.

Ground transportation industry contributes to about 14% of the global CO2 emissions. Therefore, any effort in reducing global CO2 needs to include the design of cleaner and more energy efficient vehicles. Their design needs to be optimized for the real-world conditions. Using wind tunnels that can only reproduce idealized conditions quite often does not translate into real-world on-road CO2 reduction and improved energy efficiency. Several recent studies found that very rarely can the real-world environment be represented by turbulence-free conditions simulated in wind tunnels. The real-world conditions consist of both transversal flow velocity component (causing an oncoming yaw flow) as well as large-scale turbulent fluctuations, with length scales of up to many times the size of a vehicle. The study presented in this paper shows how the realistic wind affects the aerodynamics of the vehicle.

The DrivAer model, a detailed generic open source vehicle geometry, was introduced a few years ago and accepted widely from industry and academia for research in the field of automotive aerodynamics. This paper presents the evaluation of the aerodynamic properties of the 25% scale DrivAer model in both, CFD and in wind tunnel experiment. The results not only include aerodynamic drag and lift but also provide detailed investigations of the flow field around the vehicle. In addition to the available geometries of the DrivAer model, individual changes were introduced created by morphing the geometry of the baseline model. A good correlation between CFD and experiment could be achieved by using a CFD setup including the geometry of the wind tunnel test section. The results give insight into the aerodynamics of the DrivAer model and lead to a better understanding of the flow around the vehicle.

The management of surface water flows driven from the wind screen by the action of wipers and aerodynamic shear is a growing challenge for automotive manufacturers. Pressure to remove traditional vehicle features, such as A-Pillar steps for aesthetic, aeroacoustic and aerodynamic reasons increases the likelihood that surface water may be convected over the A-Pillar and onto the front side glass where it can compromise drivers’ vision. The ability to predict where and under which conditions the A-Pillar will be breached is important for making correct design decisions. The use of numerical simulation in this context is desirable, as experimental testing relies on the use of aerodynamics test properties which will not be fully representative, or late-stage prototypes, making it difficult and costly to correct issues. This paper provides an update on the ability of simulation to predict A-Pillar overflow, comparing physical and numerical results for a test vehicle.

The implementation of an advanced process for the aerodynamic development of cab-over type heavy trucks at China FAW Group Corporation (FAW) requires a rigorous validation of the tools employed in this process. The final objective of the aerodynamic optimization of a heavy truck is the reduction of the fuel consumption. The aerodynamic drag of a heavy truck contributes up to 50% of the overall resistance and thus fuel consumption. An accurate prediction of the aerodynamic drag under real world driving conditions is therefore very important. Tools used for the aerodynamic development of heavy trucks include Computational Fluid Dynamics (CFD), wind tunnels and track and road testing methods. CFD and wind tunnels are of particular importance in the early phase development.

The ultimate goal for vehicle aerodynamicists is to develop vehicles that perform well on the road under real-world conditions. One of the most important metrics to evaluate vehicle performance is the drag coefficient. However, vehicle development today is performed mostly under controlled settings using wind tunnels and computational fluid dynamics (CFD) with artificially uniform upstream conditions, neglecting real-world effects due to road turbulence from wind and other vehicles. Thus, the drag coefficients computed with these methods might not be representative of the real performance of the car on the road. This might ultimately lead engineers to develop design solutions and aerodynamic devices which, while performing well in idealized conditions, do not perform well on the road. For this reason, it is important to assess the vehicle’s drag as seen in real-world environments. An effort in this direction is represented by using the wind-averaged drag.

The primary purpose of this paper is to correlate the CFD simulations performed using PowerFLOW, a Lattice Boltzmann based method, and wind tunnel tests performed at a wind tunnel facility on 1/8th scaled tractor-trailer models. The correlations include results using an aerodynamic-type tractor paired with several trailer configurations, including a baseline trailer without any aerodynamic devices as well as combinations of trailer side skirts and a tractor-trailer gap flow management device. CFD simulations were performed in a low blockage open road environment at full scale Reynolds number to understand how the different test environments impact total aerodynamic drag values and performance deltas between trailer aerodynamic devices. There are very limited studies with the Class-8 sleeper tractor and 53ft long trailer comparing wind tunnel test and CFD simulation with and without trailer aerodynamic device. This paper is to fill this gap.

Trailer positioning plays a significant role in the overall aerodynamics of a tractor-trailer combination and varies widely depending on configuration and intended use. In order to minimize aerodynamic drag over a range of trailer positions, adjustable aerodynamic devices may be utilized. For maximum benefit, it is necessary to determine the optimal position of the aerodynamic device for each trailer position. This may be achieved by characterizing a two-dimensional design space consisting of trailer height and tractor-trailer gap length, with aerodynamic drag as the response. CFD simulations carried out using a Lattice-Boltzmann based method were coupled with modeFRONTIER for the creation of multiple Kriging Response Surfaces. Simulations were carried out in multiple phases, allowing for the generation of intermediate response surfaces to estimate predictive error and track response surface convergence.

Brake disc materials are being utilised that have low noise/dust properties, but are sensitive to contamination by surface water. This drives large dust shields, making brake cooling increasingly difficult. However, brake cooling must be delivered without compromising aerodynamic drag and hence CO2 emissions targets. Given that front brake discs sit in a region of geometric, packaging and flow complexity optimization of their performance requires the analysis of thermal, aerodynamic and multi-phase flows. Some of the difficulties inherent in this task would be alleviated if the complete analysis could be performed in the same CAE environment: utilizing common models and the same solver technology. Hence the project described in this paper has sought to develop a CFD method that predicts the amount of contamination (water) that reaches the front brake discs, using a standard commercial code already exploited for both brake disc thermal and aerodynamics analysis.

Modern aerodynamic Class 8 freight tractors can improve vehicle freight efficiency and fuel economy versus older traditional style tractors when pulling Canadian style A- or B-Train double trailer long combination vehicles (LCV's) at highway speeds. This paper compares the aerodynamic performance of a current generation aerodynamic tractor with several freight hauling configurations through computational fluid dynamics evaluations using the Lattice-Boltzmann methodology. The configurations investigated include the tractor hauling a standard 53′ trailer, a platooning configuration with a 30′ separation distance, and an A-Train configuration including two 48′ trailers connected with a dolly converter. The study demonstrates CFD's capability of evaluating extremely long vehicle combinations that might be difficult to accomplish in traditional wind tunnels due to size limitations.

The development of a new Dongfeng Heavy truck had very strict targets for fuel consumption. As the aerodynamic drag plays a crucial role for the fuel consumption, a low drag value had to be achieved. It was therefore essential to include evaluation and optimization of the aerodynamics in the development process. Because wind tunnel facilities were not available, the complete aerodynamics development was based on digital simulation. The major portion of the aerodynamic optimization was carried out during the styling phase where mirrors, sun visor, front bumper and aero devices were optimized for drag reduction. For optimizing corner vanes and mud guards, self-soiling from the wheel spray was included in the analysis. The aero results did also show that cooling air flow rates are sufficiently high to ensure proper cooling. During the detailed engineering phase an increase of the drag above the target required further optimization work to finally reach the target.

As part of the United States Department of Energy's SuperTruck program, Volvo Trucks and its partners were tasked with demonstrating 50% improvement in overall freight efficiency for a tractor-trailer, relative to a best in class 2009 model year truck. This necessitated that significant gains be made in reducing aerodynamic drag of the tractor-trailer system, so trailer side-skirts and a trailer boat-tail were employed. A Lattice-Boltzmann based simulation method was used in conjunction with a Kriging Response Surface optimization process in order to efficiently describe a design space of seven independent parameters relating to boat-tail and side-skirt dimensions, and to find an optimal configuration. Part 1 concerns a fully-skirted tractor-trailer system, and consists of an initial phase of optimization, followed by a mid-project re-evaluation of constraints, and an additional period of optimization.

The increasing importance of reducing greenhouse gas emissions and the ongoing evolution of vehicle-to-vehicle connectivity technologies have generated significant interest in platooning for commercial vehicles, where two or more vehicles travel in same traffic lane in relatively close proximity. This paper examines the effect of platooning on four increasingly aerodynamic tractor-trailer configurations, using a Lattice Boltzmann based CFD solver. Each platoon consisted of three identical tractor-trailer configurations traveling in the same lane at 65mph. Two different vehicle to vehicle gaps were studied, 5m and 9m, in addition to singleton (solitary) vehicles, representing an effectively infinite gap. Aerodynamic drag for the lead, middle, and trailing vehicle in the platooning configurations were compared to the corresponding single vehicle tractor-trailer configuration.

Aerodynamic evaluation of vehicles using static yaw angle changes in wind tunnel testing and numerical simulation has been used as standard practice for evaluating vehicle performance under a range of wind conditions. However, this approach does not consider dynamic wind effects coming from changing wind conditions, passing other vehicles and roadside obstacles, and transient non-uniform wind conditions coming from environmental turbulence. In previous work by the authors, computational fluid dynamics (CFD) simulation methodology for considering dynamic wind conditions and on-road turbulence was demonstrated, showing the important effects of the wind conditions on the vehicle aerodynamics. The technique allows the vehicle to be tested under a range of transient gust conditions, also accounting for wind turbulence coming from upstream vehicles and natural environmental wind fluctuations.

In the development of an FAW SUV, one of the goals is to achieve a state of the art drag level. In order to achieve such an aggressive target, feedback from aerodynamics has to be included in the early stage of the design decision process. The aerodynamic performance evaluation and improvement is mostly based on CFD simulation in combination with some wind tunnel testing for verification of the simulation results. As a first step in this process, a fully detailed simulation model is built. The styling surface is combined with engine room and underbody detailed geometry from a similar size existing vehicle. From a detailed analysis of the flow field potential areas for improvement are identified and five design parameters for modifying overall shape features of the upper body are derived. In a second step, a response surface method involving design of experiments and adaptive sampling techniques are applied for characterizing the effects of the design changes.

On-highway tractor-trailer vehicles operate in a complex aerodynamic environment that includes influences of surrounding vehicles. Typical aerodynamic analyses and testing of single vehicles on test track, in wind tunnel or in computational fluid dynamics (CFD) do not account for these real world effects. However, it is possible with simulation and on-road testing to evaluate these aerodynamic interactions. CFD and physical testing of multiple vehicle interactions show that traffic interactions can impact the overall drag of leading and trailing vehicles. This paper will discuss results found in evaluating the effects of separation distances on tractor-trailer aerodynamics in on-road and CFD evaluations using a time-accurate Lattice Boltzmann Method based approach and the ramifications for improving real world prediction versus controlled single vehicle testing.

A challenge for the aerodynamic optimization of trucks is the limited availability of wind tunnels for testing full scale trucks. FAW wants to introduce a development process which is mainly based on CFD simulation in combination with some limited amount of wind tunnel testing. While maturity of CFD simulation for truck aerodynamics has been demonstrated in recent years, a complete validation is still required before committing to a particular process. A 70% scale model is built for testing in the Shanghai Automotive Wind Tunnel Center (SAWTC). Drag and surface pressures are measured for providing a good basis for comparison to the simulation results. The simulations are performed for the truck in the open road driving condition as well as in an initial digital model of the aerodynamic wind tunnel of SAWTC. A full size truck is also simulated in the open road driving condition to understand the scaling effect.

Recent regulations on greenhouse gas (GHG) emission standards for heavy duty vehicles have prompted government agencies to standardize procedures to assess aerodynamic performance of Class 8 tractor-trailers. The coastdown test procedure is the primary reference method to assess vehicle drag and other valid alternatives include wind tunnel testing and computational fluid dynamics (CFD) simulations. While there have been many published studies comparing results between simulations and wind tunnel testing, it is less well understood how to compare results with coastdown testing. Both the wind tunnel and simulation directly measure aerodynamic drag forces in controlled conditions, while coastdown testing is conducted in an open road environment, aerodynamic forces are calculated from a road load equation, and variable wind and vehicle speed introduce additional complexity.

Aerodynamic performance assessment of automotive shapes is typically performed in wind tunnels. However, with the rapid progress in computer hardware technology and the maturity and accuracy of Computational Fluid Dynamics (CFD) software packages, evaluation of the production-level automotive shapes using a digital process has become a reality. As the time to market shrinks, automakers are adopting a digital design process for vehicle development. This has elevated the accuracy requirements on the flow simulation software, so that it can be used effectively in the production environment. Evaluation of aerodynamic performance covers prediction of the aerodynamic coefficients such as drag, lift, side force and also lift balance between the front and rear axle. Drag prediction accuracy is important for meeting fuel efficiency targets, prediction of front and rear lifts as well as side force and yawing moment are crucial for high speed handling.

The Tesla Motors Model S has been designed from a clean sheet of paper to prove that no compromises to a desirable aesthetic style and world class driving experience are necessary in order to be energy efficient. Aerodynamic optimization is a major contributor to the overall efficiency of an electric vehicle and the close integration of the Design and Engineering groups at Tesla Motors was specifically arranged to process design iterations quickly and enable the fully informed development of the exterior surfaces at a very rapid pace. Clear communication and a working appreciation of each other's priorities were vital to this collaboration and underpinning this was extensive use of the powerful analysis and visualization capabilities of CFD. CFD was used to identify and effectively communicate the nature of beneficial and detrimental design features and to find ways to enhance or ameliorate them accordingly.