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Technical Paper

Optimizing the Rear Fascia Cutline Based On Investigating Deviation Sources of the Body Panel Fit and Finish

A vehicle’s exterior fit and finish, in general, is the first system to attract customers. Automotive exterior engineers were motivated in the past few years to increase their focus on how to optimize the vehicle’s exterior panels split lines quality and how to minimize variation in fit and finish addressing customer and market required quality standards. The design engineering’s focus is to control the deviation from nominal build objective and minimize it. The fitting process follows an optimization model with the exterior panel’s location and orientation factors as independent variables. This research focuses on addressing the source of variation “contributed factors” that will impact the quality of the fit and finish. These critical factors could be resulted from the design process, product process, or an assembly process. An empirical analysis will be used to minimize the fit and finish deviation.
Technical Paper

Reducing the Acoustic Surface Power of a Cooling Fan Using the Mesh Morpher Optimizer

Cooling fans have many applications in industrial and electronic fields that remove heat away from the system. The process of designing a new cooling fan with optimal performance and reduced acoustic sources can be fairly lengthy and expensive. The use of CFD with support of mesh morphing, along with the development of optimization techniques, can improve the acoustic’s performance of the fan model. This paper presents a new promising method which will support the design process of a new cooling fan with improved performance and less acoustic surface power generation. The CFD analysis is focused on reducing the acoustic surface power of a given cooling fan’s blade using the surface dipole acoustic power as the objective function, which leads to an optimized prototype design for a better performance. The Mesh Morpher Optimizer (MMO) in ANSYS Fluent is used in combination with a Simplex model of the broadband acoustic modeling.
Technical Paper

Simulation and Approximation are Effective Tools for Products Development

To stay competitive, new products require faster development time at low cost and good quality. Defense as well as commercial industries are forced to use analytical tools to stay competitive in a tough market. The use of simulation tools and approximation techniques in evaluating product performance during the early stages of the product development has a major impart on the product development efficiency, effectiveness, and lead time. Building physical prototypes of complex systems is expensive and it is difficult and time consuming to develop them. It is extremely beneficial to know as much as possible about the product performance and to optimize its dynamic characteristics before the first physical prototype is built.
Technical Paper

Optimization of Modified Car Body Using Mesh Morphing Techniques in CFD

Today's strict fuel economy requirement produces the need for the cars to have really optimized shapes among other characteristics as optimized cooling packages, reduced weight, to name a few. With the advances in automotive technology, tight global oil resources, lightweight automotive design process becomes a problem deserving important consideration. It is not however always clear how to modify the shape of the exterior of a car in order to minimize its aerodynamic resistance. Air motion is complex and operates differently at different weather conditions. Air motion around a vehicle has been studied quite exhaustively, but due to immense complex nature of air flow, which differs with different velocity, the nature of air, direction of flow et cetera, there is no complete study of aerodynamic analysis for a car. Something always can be done to further optimize the air flow around a car body.
Technical Paper

Shape Optimization of Multi-Element Airfoil Using Morphing Deformation

This work studies an optimization tool for 2D and 3D a multi-element airfoil which utilizes the power of CFD solver of a Shape Optimizer package to find the most optimal shape of multi-element airfoil as per designer's requirement. The optimization system coupled with Fluent increases the utilization and the importance of CFD solver. This work focuses on combining the high fidelity commercial CFD tools (Fluent) with numerical optimization techniques to morph high lift system. In this work strategy we performed morphing (grid deformation) directly inside the Fluent code without rebuilding geometry and the mesh with an external tool. Direct search method algorithms such as the Simplex, Compass, and Torczon are used; Navier-Stokes equations were solved for turbulent, incompressible flow using k-epsilon model and SIMPLE algorithm using the commercial code ANSYS Fluent.
Technical Paper

Aerodynamic Shape Optimization for a 3-D Multi-Element Airfoil

This paper discusses the uses of shape morphing/optimization in order to improve the lift to drag ratio for a typical 3D multi-element airfoil. A mesh morpher algorithm is used in conjunction with a direct search optimization algorithm in order to optimize the aerodynamics performance of a typical high-lift device. Navier-Stokes equations are solved for turbulent, steady-state, incompressible flow by using k-epsilon model and SIMPLE algorithm using the commercial code ANSYS Fluent. Detailed studies are done on take-off/landing flight conditions; the results show that the optimization is successful in improving the aerodynamic performance.
Technical Paper

Improving Engine Performance Through Intake Design

The power and torque output of an engine (for a Formula SAE vehicle) can be dramatically improved through good intake design. For example, performance can be improved by reducing pressure losses in the intake system, or by improving the restrictor's design to increase airflow at lower pressure drops. A plenum design with equal air distribution to all cylinders can also be helpful. In this study, four different intake designs were tested on a dynamometer and the power outcomes were compared. Based on theory and lab testing and intake system was designed to optimize throttle response as well as low-end torque; a steady flow of air passes through the throttle body and the restrictor and then into the plenum. Dynamometer testing confirmed an overall increase in torque and horsepower compared to earlier designs.
Journal Article

Developing a Transfer Function for Vehicle Ride Performance

The purpose of this paper is to develop the transfer function for the ride and handling performance for military tracked vehicle. This transfer function will be used in placed of the expensive physical hardware or simulation model for further study for robust design and optimization studies. Response Surface Methodology (RSM) approximation technique was used to develop the transfer functions. The RSM comprises of a group of statistical techniques for empirical model building and exploitation. RSM uses Design of Experiment (DOE) and multiple linear regression techniques for fitting of a response surface model that relates the output response to the design variables. The general form of the transfer function is a second order polynomial with unknown parameters to be identified. These unknown parameter were determined using the Central Composite Design (CCD) design of experiments.