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The quality of the paint application in automotive industry depends on several process parameters. Thus, finding an optimal solution based on experimental configuration is tedious and time consuming. A first step to reduce the effort is to model the application within the framework of a simulation environment. In this study, we present an approach for the systematic variation of design parameters of the paint process to quantify their influence on the quality of the paint application. Using that information the design space is reduced by neglecting the parameters with low impact and later used to predict an optimal set of input parameters for an optimal paint application.

In hybrid and electrical vehicles new challenges in meeting the drivers' expectation with regards to acoustic comfort arise. The absence of the internal combustion engine noise enhances the passengers' perception of other noise sources, such as the Heating, Ventilation and Air-Conditioning (HVAC) system. Therefore efficient and reliable numerical models able to predict flow-induced broadband noise have become a major research topic in automotive industry. In this framework, the Zonal LES coupled with the Ffowcs Williams-Hawkings (FWH) acoustic analogy are capable to simulate broadband noise from low speed axial fan. As demonstrated in previous works from the authors, this approach is able to cope with the complexity of the physical phenomena involved (i.e. turbulent noise generation, laminar-to-turbulent transition, etc.), even though the numerical model requires a careful setup of the mesh topology, boundary conditions and simulation parameters.

Stringent diesel emission regulations have been forcing constant reduction in the discharge of particulate matter and nitrogen oxide (NOx). Current state-of-the-art in-cylinder solutions are falling short of achieving these limits. For this reason engine manufacturers are looking at different ways to meet the emission regulations. Selective catalytic reduction (SCR) of oxides of nitrogen with ammonia gas is emerging as preferred technology for meeting stringent NOx emission standards across the world. SCR system designers face several technical challenges, such as avoiding ammonia slip, urea crystallization, low temperature deposits and other potential pitfalls. Simulation can help to develop a deep understanding of these technical challenges and issues, identify root causes of problems and help develop better designs. This paper describes the modeling approach for Urea Water Solution (UWS) spray and its interaction with canister walls and exhaust gases.