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Strategies for weight reduction have driven the noise treatment advanced developments with a great success considering the already mastered weight decreases observed in the last years in the automotive industry. This is typically the case for all soft trims parts. In the early 2010's a typical european B-segment car soft trims weights indeed 30 to 40% less than in the early 2000's years. The main driver behind such a gap has been to combine insulation and absorption properties on a single part while increasing the number of layers. This product-process evolution was conducted using a significant improvement in the simulation capacities. In that sense, several studies presenting very good correlation results between Transmission Loss measurements and finite elements simulations on dashboard or floor insulators were presented. One may consider that those kinds of parts have already achieved a considerable improvement in performance.

Cooling drag is the increase in the total drag due to the internal flow in the cooling system. Because of the high flow resistance in the heat exchanger the momentum of the fluid needed for engine cooling usually is dissipated nearly completely. The resulting drag penalty can be approximated by the so called ram drag. For ground vehicles the cooling drag is typically lower than this approximation due to positive interference of the cooling flow with the general flow around the vehicle. Different mechanisms for the positive interference have been described in the literature. Inlet interference as well as outlet interference can result in significant reduction of the share of the cooling drag. Positive outlet interference is obtained, when the remaining kinetic energy of the cooling flow contributes significant thrust to the overall momentum balance.

In open jet wind tunnels with high blockage ratios a sharp rise in drag is observed for models approaching the nozzle exit plane. The physical background for this rise in drag will be analyzed in the paper. Starting with a basic analysis of the dependencies of the effect on model and wind tunnel properties, the key parameters of the problem will be identified. It will be shown using a momentum balance and potential flow theory that interaction between model and nozzle exit can result in significant tunnel-induced gradients at the model position. In a second step, a CFD-based investigation is used to show the interaction between nozzle exit and a bluff body. The results cover the whole range between open jet and closed wall test section interaction. The model starts at a large distance from the nozzle, then moves towards the nozzle, enters the nozzle and is finally completely inside the nozzle.

Driven by the growing internet and remote connectivity of automobiles, combined with the emerging trend to automated driving, the importance of security for automotive systems is massively increasing. Although cyber security is a common part of daily routines in the traditional IT domain, necessary security mechanisms are not yet widely applied in the vehicles. At first glance, this may not appear to be a problem as there are lots of solutions from other domains, which potentially could be re-used. But substantial differences compared to an automotive environment have to be taken into account, drastically reducing the possibilities for simple reuse. Our contribution is to address automotive electronics engineers who are confronted with security requirements. Therefore, it will firstly provide some basic knowledge about IT security and subsequently present a selection of automotive specific security use cases.

One main goal of the automotive industry is to reduce the aerodynamic drag of passenger vehicles. Therefore, a deeper understanding of the flow field is necessary. Time-resolved data of the flow field is required to get an insight into the complex unsteady flow phenomena around passenger vehicles. This data helps to understand the temporal development of wake structures and enables the analysis of the formation of vortical structures. Numerical simulations are an efficient method to analyze the time-resolved data of the unsteady flow field. The analysis of the steady and unsteady numerical data is only relevant for aerodynamic developments in the wind tunnel, if the predicted temporal evolving structures of a passenger vehicle’s simulated flow field correspond to the structures of the flow field in the wind tunnel. In this study, time-resolved measurements of the empty wind tunnel and a notchback passenger vehicle in the wind tunnel are conducted.

A region with floor boundary-layer suction upstream of the vehicle to remove the oncoming boundary layer is often used in automotive wind tunnels. These suction systems inevitably change the empty-tunnel pressure gradient. In this paper, the empty-tunnel pressure gradient created by the use of boundary layer suction and its effect on measured drag are investigated. By using excess suction - more suction than necessary to remove the floor boundary layer – it was possible to show experimentally that the major part of the drag increase due to boundary layer suction is created by unintended gradient effects. Only a minor part of the drag increase is due to the increased flow velocities at the lower parts of the vehicle, or in other words, due to the improved ground simulation. A theoretical model, using the concept of horizontal buoyancy to predict the gradient effect, is proposed. The model is compared to the experimental results as well as to CFD calculations.

Hydromechanical sheet forming (AHU®) is an innovative production process with interesting applications, possibilities and potential for the cost-effective manufacture of automobile body parts, particularly with regard to the use of new and improved steels. The targeted, component-specific use of hydro-mechanical sheet forming in automobile construction promises to deliver outstanding results from both a technological and economic point of view.

For the aerodynamic development of an aircraft the induced drag is an important quantity and it has a significant impact on the design of the wing. The induced drag corresponds to the power requirement of the wing to generate the necessary lift. In many cases this is the dominant source of drag for aircraft. In ground vehicle aerodynamics the concept of induced drag up to now has attracted much less attention. This is partly due to the fact, that vehicle aerodynamicists usually optimize the vehicles to generate little or no lift. The second reason is that it is much more difficult for a ground vehicle to separate the total drag into the different contributions. During wind tunnel tests of vehicles with and without ground simulation some astonishing results were found, especially when comparing results for different rear end shapes.

Audi's new full scale aeroacoustic wind tunnel is under full operation now. The new facility is designed for full scale automotive testing of aerodynamics and aeroacoustics for vehicles up to 3 m2 frontal area at wind speeds up to 300 kph. The highlights are the unique ground simulation system with boundary layer suction and a 5-belt-system, and the extremely low background noise of only 60 dB(A) at 160 kph. First the background of the project is illustrated and the need for the special features of the tunnel is deduced form the industrial requirements. Then an overview of the facility design is given with a detailed description of the key technical components. The calibration of the self-correcting test section will be discussed and the physical background for it will be examined more closely. For the calibrated wind tunnel the results of two correlation tests including open jet as well as closed wall wind tunnels show a reasonable conformity.