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This report presents the results of a CFD study to develop a bodywork package to improve the aerodynamic performance of the Brigham Young University (BYU) Electric Streamliner. A comparison of the pressure distribution and the flow around the baseline and final ‘recommended’ configuration is also presented. The effect of the CFD developed body geometry to the vehicle has been to increase downforce by almost 300lbf when it is at 200mph, while reducing drag by 8.5lbf. The final lift to drag ratio is -1.56 as compared to the .67 baseline.

Although the aerospace production process is much better controlled than the process in other industries, it remains true that very small manufacturing variability exists in the geometrical parameters (flange thicknesses, hole diameters …) as well as in material properties.). Also the medical, nuclear, and even the toy industry manufacturers assemble their products to very controlled and tight tolerances, thus receiving the always more stringent quality requirements imposed by customers, regulations and safety. However, despite this clear trend towards improved quality in products, in the current design process, the effect of this manufacturing variability is usually compensated for by applying safety factors. This is not an ideal situation, as it may lead to slightly over-designed structures. A much more promising approach is to include probabilistic models of design variables into the mechanical simulation process.