Browse Topic: Computational fluid dynamics (CFD)

Items (4,308)
When a vehicle is driven at high speed, there exists intricate flow pattern and vortex shedding at the side window area with intense pressure fluctuation. A significant dynamic pressure difference between the vehicle's exterior and interior can render the side window sealing system vulnerable to aspiration. This susceptibility can lead to the generation of leakage noise, adversely affecting acoustic comfort in the vehicle's cabin. This paper delves into the aspiration properties of glassrun seal system under time-varying pressure difference. A nonlinear finite element model of the glassrun seal was established to simulate the quasi-static deformation of the sealing strip during installation process, which aims to obtain the deformed geometric shape and residual stress after this process. Then, the exterior flow field of the glassrun sealing area of a simplified vehicle model was calculated with CFD simulation to obtain the hydrodynamic pressure excitation acting on the outer surface of
Li, HanqiHe, YinzhiZhang, LijunZhang, YongfengYu, WuzhouJiang, ZaixiuBlumrich, ReinhardWiedemann, Jochen
Within automobiles, the HVAC is a critical system to regulate the occupants’ thermal comfort. However, at its high operating speeds, it can contribute significantly to the overall sound levels perceived by the cabin occupants, impacting their experience. This is especially true in the case of electric vehicles due to their overall quieter operation. This work has the intention to validate HVAC noise predictions using computational fluid dynamics (CFD) simulations. In addition, CFD simulations provide detailed flow field insights which are essential to identify and rank the main noise sources, and it ultimately allows a better understanding of the physical mechanisms of noise generation on similar systems. These insights are very difficult, if not impossible, to obtain with physical testing and are key to designing a quiet and efficient HVAC system. Sound levels were measured experimentally at eight different locations inside of a Class-8 Nikola TRE hydrogen fuel cell electric semi
Ihi, RafaelFougere, NicolasPassador, StephenWoo, SangbeomKim, JamesDesouky, Mohamed
This study introduces a computational approach to evaluate potential noise issues arising from liftgate gaps and their contribution to cabin noise early in the design process. This computational approach uses an extensively-validated Lattice Boltzmann method (LBM) based computational fluid dynamics (CFD) solver to predict the transient flow field and exterior noise sources. Transmission of these noise sources through glass panels and seals were done by a well-validated statistical energy analysis (SEA) solver. Various sealing strategies were investigated to reduce interior noise levels attributed to these gaps, aiming to enhance wind noise performance. The findings emphasize the importance of integrating computational tools in the early design stages to mitigate wind noise issues and optimize sealing strategies effectively.
Moron, PhilippeJantzen, AndreasKim, MinsukSenthooran, Sivapalan
The advancement of civil supersonic aircraft is significantly constrained due to the intense noise generated by the shock waves that form during cruise, commonly referred to as the sonic boom. Due to these excessive noise levels, regulatory authorities currently ban supersonic flights over land. This study presents a comprehensive methodology to evaluate sonic booms in mid- and far-field regions, starting with a precise estimation of the near-field pressure signature produced by the shock wave system. While high-fidelity computational fluid dynamics (CFD) techniques typically provide near-field sonic boom predictions, specific propagation models must be used at greater distances, as CFD becomes prohibitively expensive beyond approximately 10 km. The focus of this research is a comparative analysis of a low-fidelity propagation approach, such as Whitham’s equation, and a high-fidelity CFD-based approach for assessing sonic boom propagation over medium range distances. The low-fidelity
Glorioso, AntimoFasulo, GiovanniPetrosino, FrancescoBarbarino, Mattia
This paper presents a fully parallelized Computational Acoustics (CA) module, integrated within the Simerics-MP+ platform, developed for the prediction of noise source power and far-field propagation across a range of Computational Fluid Dynamics (CFD) applications. Utilizing the Ffowcs Williams-Hawkings (FWH) acoustic analogy, the CA module seamlessly integrates with existing CFD workflows, offering minimal computational overhead with less than a 5% increase in runtime. Extensive validation has been conducted against analytical, numerical, and experimental data in various acoustic scenarios, including monopole and dipole noise emissions, flow around slender bodies, circular cylinders and aero-propellers. These validation studies underscore the reliability of the framework in accurately identifying noise sources and assessing the impact of design modifications, significantly reducing the need for expensive physical prototyping in industries such as automotive and aerospace. Building
Taghizadeh, SalarCzwielong, FelixBecker, StefanVarghese, JoelRaj, GowthamDhar, Sujan
Wind noise is one of the largest sources to interior noise of modern vehicles. This noise is encountered when driving on roads and freeways from medium speed and generates considerable fatigue for passengers on long journeys. Aero-acoustic noise is the result of turbulent and acoustic pressure fluctuations created within the flow. They are transmitted to the passenger compartment via the vibro-acoustic excitation of vehicle surfaces and underbody cavities. Generally, this is the dominant flow-induced source at low frequencies. The transmission mechanism through the vehicle floor and underbody is a complex phenomenon as the paths to the cavity can be both airborne and structure-borne. This study is focused on the simulation of the floor contribution to wind noise of two types of vehicles (SUV and Sports car), whose underbody structure are largely different. Aero-Vibro-acoustic simulations are performed to identify the transmission mechanism of the underbody wind noise and contribution
Mordillat, PhilippeZerrad, MehdiErrico, Fabrizio
During the last decades there has been a renewed interest in the development of a new generation of supersonic aircraft for civil purposes with limited implications to the environment. However, the noise generated by supersonic aircraft during supersonic flight, commonly referred to as "sonic boom", still creates annoyance to community on the ground that prohibits supersonic overland flight. To prepare for the advent of a new generation of supersonic aircraft and to define new regulations for them, an increasing number of sonic boom studies is being published. This paper presents numerical simulations of the sonic boom of a hypersonic (Mach 5) aircraft concept during the full flight envelope, including a sensitivity analysis of the two parameters velocity and altitude. The extensive simulations characterize the sonic boom distribution on ground, which is usually referred to as “sonic boom carpet”, caused by the aircraft for different speeds between Mach 1.2 and Mach 5.0, and for two
Graziani, SamueleJäschke, Jacob JensViola, NicoleGollnick, Volker
The ported shroud casing treatment for turbocharger compressors is desirable for mitigating broadband/whoosh noise and enhancing boost pressures at low to mid flow rates. Yet, it is accompanied by elevated narrowband noise at the blade-pass frequency (BPF). Compressor BPF noise occurs at high frequencies where wave propagation is often multi-dimensional, rendering traditional planar wave silencers invalid. An earlier work introduced a novel reflective high-frequency silencer (baseline) targeting BPF noise in the 8-12 kHz range using an “acoustic straightener” that promoted planar wave propagation along arrays of quarter-wave resonators (QWRs). The design, however, faced challenges with high-amplitude tonal noise generation at specific flow conditions due to flow-acoustic coupling at the opening of the QWRs, thereby compromising the noise attenuation. The current study explores two QWR interface geometries that weaken the coupling, including linear and saw-tooth ramps on the upstream
Sriganesh, PranavSelamet, Ahmet
Large eddy simulations (LES) of two HVAC duct configurations at different vent blade angles are performed with the GPU-accelerated low-Mach (Helmholtz) solver for comparison with aeroacoustics measurements conducted at Toyota Motor Europe facilities. The sound pressure level (SPL) at four near-field experimental microphones are predicted both directly in the simulation by recording the LES pressure time history at the microphone locations, and through the use of a frequency-domain Ffowcs Williams-Hawking (FW-H) formulation. The A-weighted 1/3 octave band delta SPL between the two vent blades angle configurations is also computed and compared to experimental data. Overall, the simulations capture the experimental trend of increased radiated noise with the rotated vent blades, and both LES and FW-H spectra show good agreement with the measurements over most of the frequency range of interest, up to 5,000Hz. For the present O(30) million cell mesh and relatively long noise data collection
Besem-Cordova, Fanny M.Dieu, DonavanWang, KanBrès, Guillaume A.Delacroix, Antoine
Improving electric vehicles’ overall thermal management strategy can directly or indirectly improve battery efficiency and vehicle range [1]. In this study, the effect of the coolant type used in BTMS (battery thermal management system) units used for heating batteries in cold weather conditions was investigated in electric buses. In this investigation, tests were performed with two types of antifreeze, which have different characteristics. The study evaluated the impact of coolant flow, BTMS circulation pump performance, and battery heating using these two types of antifreeze in the BTMS coolant line. In addition to carrying out tests, 1D computational fluid dynamics models’ simulations were carried out for both types of antifreeze, and the results were validated with experimental findings. In this study, a 12-m EV Citivolt vehicle of Anadolu Isuzu was used for tests. As a result, it was observed that differences in the properties of the antifreeze that is used in BTMS coolant line
Çetir, ÖzgürBirgül, Çağrı Emre
Wind noise is an important indicator for evaluating cabin comfort, and it is essential to accurately predict the wind noise inside the vehicle. In the early stage of automotive design, since the geometry and properties of the sealing strip are often unknown, the contribution of the sealing strip to the wind noise is often directly ignored, which makes the wind noise obtained through simulation in the pre-design stage to be lower than the real value. To investigate the effect of each seal on wind noise, an SUV model was used to simulate the cases of not adding body seals, adding window seals, and further adding door seals, respectively. The contribution of each seal to wind noise was obtained and verified by comparing it with the test results. The influence of the cavity formed at the door seal was also addressed. In the simulations, a CFD solver based on the lattice Boltzmann method (LBM) was used to solve the external flow field, and the noise transmitted into the interior of the
Zhang, YingchaoHe, TengshengWang, YuqiNiu, JiqiangZhang, ZheShen, ChunZhang, Chengchun
The Electric Control Unit (ECU) is a crucial computing unit responsible for engine regulating various functions. However, non-airflow thermal design due to the complexity of engine bay turbulent flow simulation is limiting ECU’s potential with the increasing demand of computation power consumption, thermal design faced additional challenges. Moreover, the lack of standardized ECU design guidelines forced substantial investments in customized thermal solutions for different engine bay packaging. Through this research, the method of finding representative points of ambient temperature efficiently and reliably is investigated, so that thermal design can be achieved by estimating flow properties during the ECU design stage efficiently. This research involves studying the effects of airflow on ECU cooling using experimental and numerical analysis in Computational Fluid Dynamics (CFD). Alongside the representative points of ambient temperature uncovered from the numerical result
Zhong, JiajunInaba, KazuakiYamaguchi, RyotaYasui, RyutaUmeno, Masafumi
Swirl chamber combustion system is commonly used for IDI (In-Direct Injection) diesel engine. It is characterized by swirl combustion chamber arranged in cylinder head, main combustion chamber with shallow piston recess and connecting throat where fuel spray and flame mixture is ejected out from the swirl chamber to the main chamber [1]. Fuel is supplied in the swirl chamber and a pintle type nozzle is often used in this type engine as its simple structure and robustness for operating condition. In this paper, numerical simulation of a pintle nozzle spray was focused on and simulated results were compared with high speed photo data obtained in a constant volume vessel (CVV). Spray angle and tip penetration were mainly evaluated, but simulated angle and penetration could not be matched simultaneously to these characteristics of the pintle nozzle spray when conventional spray models were used for the simulation. To overcome this mismatch, “Multi-hole replacement model” was newly
Okazaki, TadaoFujiwara, Tsukasa
In recent years, climate change and geopolitical instability have intensified the focus on sustainable power generation. This shift seeks alternatives that balance environmental impact, cost-effectiveness, and practicality. Specifically, in transportation and power generation, electric motors face challenges against internal combustion engines due to the high cost and mass of batteries required for energy storage. This makes electric solutions less favorable for these sectors. Conversely, internal combustion engines, when properly fueled, offer cost-effectiveness and a quasi-environmentally-neutral option. To address these challenges, researchers have explored e-fuels derived from renewable sources as a carbon-neutral supply for internal combustion engines. Among these, hydrogen is particularly promising. In hydrogen-powered internal combustion engines, 3D-CFD (Computational Fluid Dynamics) in-cylinder models are crucial. Once validated, these models can speed up the design process. A
Sfriso, StefanoBerni, FabioBreda, SebastianoFontanesi, StefanoCordisco, IlarioLeite, Caio RamalhoBrequigny, PierreFoucher, Fabrice
The growing demand for sustainable transportation solutions and renewable energy storage systems has heightened the necessity for precise and effective prediction of battery thermal performance. However, achieving both precision and efficiency poses a challenge, necessitating exploration into diverse methodologies. The conventional use of Computational Fluid Dynamics (CFD) offers a comprehensive insight into thermal dynamics but prioritizes precision over efficiency. To enhance the efficiency of this traditional approach, numerous reduced-order modeling techniques have emerged, and the concept of Machine Learning (ML) presents a distinct avenue for enhancing simulation capabilities, particularly in the context of mobility solutions. This paper presents a novel approach to accelerate battery thermal analysis by integrating CFD and ML. The CFD simulations provide an intricate understanding of the thermal dynamics within batteries, encompassing fluid flow and temperature distributions
Devarajan, GurudevanVaidyanathan, GaneshBhave, AjinkyaJi, LichaoWang, JiaoZhou, WeiHe, JiguangShi, Pengfei
The rise of electric vehicles (EVs) highlights the need to transition to a renewable energy society, where power is generated from sustainable sources. This shift is driven by environmental, economic, and energy security concerns. However, renewable energy sources like wind and solar are intermittent, necessitating extensive energy storage systems. Vanadium redox flow batteries (VRFBs) are promising for large-scale energy storage due to their long cycle life, scalability, and safety. In VRFBs, cells are typically connected in series to increase voltage, with electrolytes introduced through parallel flow channels using a single manifold. This design, while simple and low in pressure drop, often leads to imbalanced flow rates among cells, affecting performance. Balancing flow rates is crucial to minimize uneven overpotential and enhance durability, presenting an optimization challenge between achieving uniform flow and minimizing pressure drop. This study developed numerical models to
Suwanpakdee, NutAiemsathit, PorametCharoen-amornkitt, PatcharawatSuzuki, TakahiroTsushima, Shohji
The future potential of an opposed-piston two-stroke (OP2S) engine has attracted the attention of researchers worldwide as it offers a high thermal efficiency and power-to-weight ratio with a simple engine configuration. This engine can be used with low-carbon fuels and hydrogen to reduce greenhouse gas emissions. However, the two-stroke operation has always been limited by its low scavenging efficiency and short-circuit of fresh charge. The current work is focused on optimizing scavenging efficiency and short-circuit in a small 200 cc single-cylinder OP2S SI engine using 3-D computational fluid dynamic (CFD) simulations. The effect of four parameters, namely, area of intake ports, area of exhaust ports, and angular orientations of intake ports (swirl and tilt) on scavenging efficiency and short-circuit, has been assessed and optimized. A Latin-hypercube based Design of Experiments (DoE) methodology is used to sample the design space spanning over a range of four parameters. A response
Singh, SaurabhBoggavarapu, PrasadHimabindu, M.Ravikrishna, R.V.
Since proportion of wall heat loss takes as high as 20-30% of the total engine heat loss, the reduction of wall heat loss is considered as an effective way to improve the engine thermal efficiency. The heat transfer near the wall boundary layer plays a significant role on the exploration about the mechanism of wall heat transfer which contributes to figuring out the approach to the reduction of wall heat loss. However, the near wall characteristics of heat transfer are still unclear. In this study, the premixed lean methane flame propagation was captured by the high-speed schlieren and the flame behavior in the near-wall region was investigated by the micro CH* chemiluminescence. The temporal histories of the wall temperature and the heat flux are measured by the co-axial thermocouple. The factors including the convective heat transfer coefficient and non-dimensionless numbers, Nusselt number and Reynolds number, were used to characterize the near wall characteristics. Also, the
Xuefeng, XueRun, ChenTie, Li
Urea-based selective catalytic reduction (SCR) systems are widely used to meet stringent NOx emission standards in industrial diesel engines. However, suboptimal design of the urea-water solution (UWS) mixing pipes in SCR systems can lead to the formation of urea-derived solid deposits, which may adversely affect the system performance and reliability. Although recent advancements in deposit simulation technology using three-dimensional Computational Fluid Dynamics (3D CFD) have significantly improved the performance and compactness of mixing pipes, assessing deposit formation across all operating and environmental conditions remains challenging due to high simulation costs. This study introduces a novel computational method for predicting the formation and temperature of permanent liquid films from UWS injection which are closely related to deposit formation, along with new deposit evaluation criteria based on them. This proposed method integrates a one-dimensional heat transfer model
Sugimoto, KazumaKawabe, Ken
This paper explains transient, computationally rigorous, three-dimensional and one-dimensional multiphase CFD analysis of engine oil drainback system and lubrication system for predicting aeration. Aeration of engine oil is an important factor as it affects working of Hydraulic Lash Adjusters, bearings performance and it reduces lube system pressure itself which is detrimental for the entire engine. In this work specifically effect of engine tilting on lube oil aeration is presented. When engine is tilted, crankshaft and connecting rod/s are dipped in to oil, which creates air bubbles. These air bubbles travel to lube pump and then to the engine lube system. Therefore, it is essential to model aeration in Engine crankcase, Oil pan and Lube system for the purpose of predicting oil pressure reduction in lube system. The problem under consideration is spread over a bigger zone, involves rotating and translating components, passage’s dimensions are varying from microns to meters and
Tawar, Ranjit RamchandraBedekar, Sanjeev
The main purpose of the semi-active hydraulic damper (SAHD) is for optimizing vehicle control to improve safety, comfort, and dynamics without compromising the ride or handling characteristics. The SAHD is equipped with a fast-reacting electro-hydraulic valve to achieve the real time adjustment of damping force. The electro-hydraulic valve discussed in this paper is based on a valve concept called “Pilot Control Valve (PCV)”. One of the methods for desired force characteristics is achieved by tuning the hydraulic area of the PCV. This paper describes a novel development of PCV for practical semi-active suspension system. The geometrical feature of the PCV in the damper (valve face area) is a main contributor to the resistance offered by the damper. The hydraulic force acting on the PCV significantly impacts the overall performance of SAHD. To quantify the reaction force of the valve before and after optimization under different valve displacements and hydraulic pressures were simulated
Chintala, ParameshHornby, Ryan
Amphibious vehicles are widely used in civil and military scenarios due to their excellent driving performance in water and on land, unique application scenarios and rapid response capabilities. In the field of civil rescue, the hydrodynamic performance of amphibious vehicles directly affects the speed and accuracy of rescue, and is also related to the life safety of rescuers. In the existing research on the hydrodynamic performance of amphibious vehicles, seakeeping performance has always been the focus of research by researchers and amphibious vehicle manufacturers, but most of the existing research focuses on the navigation performance of amphibious vehicles in still water. In actual application scenarios, amphibious vehicles often face complex water conditions when performing emergency rescue tasks, so it is very important to study the navigation performance of amphibious vehicles in waves. Aiming at the goal of studying the navigation performance of amphibious vehicles in waves
Zhang, Yu
As the automotive industry increasingly shifts toward electrification, reducing vehicle drag becomes crucial for enhancing battery range and meeting consumer expectations. Additionally, recent regulations such as WLTP can require car manufacturers to provide reliable drag data for vehicles as they are configured, as is the case in Europe. Vehicle and tire manufacturers can assess tire impacts on vehicle performance through testing. However, to improve designs, it is essential to identify which tire features influence the flow field and overall vehicle performance. Physical tests measure tire behavior under load, but isolating contact patch and tire bulge effects is difficult, as both change together. Simulation allows independent analysis of these factors—something that physical testing alone cannot achieve. This paper investigates the aerodynamic impact of realistic tire deformation parameters—specifically, bulge and contact patch deformations—using PowerFLOW® from Dassault Systèmes
Martinez Navarro, AlejandroParenti, GuidoShock, Richard
The automotive aerodynamic development relies on wind tunnel testing and Computational Fluid Dynamics (CFD), where the former provides reliable values to be used for fuel economy calculations, and the latter enables the investigation of flow features responsible for improvement/degradation of the average large-scale performances in terms of aerodynamic coefficients. The abovementioned procedure overlooks a crucial factor however: natural wind. The speed and the direction of natural wind encountered while driving alters the vehicle’s effective yaw angle. Such condition implies that the minimization of the drag coefficient at zero-yaw, commonly performed through wind tunnel and CFD simulations in an industrial context, may not yield real-world optimal shapes. While it is possible to reproduce natural wind-like conditions in a wind tunnel using flaps, for example, the input signal to the flap system must be available beforehand, and such key element is the focus of the present research
Nucera, FortunatoOnishi, YasuyukiMetka, Matt
The adoption of hydrogen as a sustainable replacement for fossil fuels is pushing the development of internal combustion engines (ICEs) to overcome the technical limitations related to its usage. Focusing on the fuel injector in a DI configuration, it must guarantee several targets such as the adequate delivery of hydrogen mass for the given operating condition and the proper mixture formation in the combustion chamber playing a primary role in reaching the target performance in H2-ICEs. Experimental campaigns and computational fluid dynamics simulations can be used as complementary tools to provide a deep understanding of the injector behaviour and to drive design modifications in a quick and effective way. In the present work an outward opening, piezo-actuated injector purposely designed to be fuelled with hydrogen is tested on several operating conditions to evaluate its performance in terms of delivered mass flow and jet morphology using the Schlieren imaging technique. To
Pavan, NicolòCicalese, GiuseppeGestri, LucaFontanesi, StefanoBreda, SebastianoMechi, MarcoVongher, SaraPostrioti, LucioBuitoni, GiacomoMartino, Manuel
This paper summarizes work on the application of a new and fully parallelized native GPU-based finite-volume solver on the DrivAER Notchback configuration using a wall-function LES approach. A series of meshes generated using a Rapid-Octree strategy have been investigated, and results for drag, surface pressure coefficient and velocity profile are compared with available experimental data.
Menter, FlorianDalvi, AshwiniFlad, DavidSharkey, Patrick
Existing technical literature has primarily focused on the upstream wake effects of single-seater race cars during overtaking, often neglecting the critical factor: crosswinds. This study presents a quantitative computational fluid dynamics (CFD) analysis of how crosswinds impact the aerodynamic loads of interacting race car models during an overtake manoeuvre. For numerical validation purposes, a wind tunnel experimental campaign was carried out on a 35%-scale hill climb race car model to evaluate aerodynamic forces and wake pressure mappings at different ride heights. RANS-based simulations were performed to assess the impact of crosswinds (β = 2°, 6°, 10°) on an isolated race car. Subsequently, a quasi-static approach was used to quantify the effect of crosswind (β = 10°) on an overtaking car under different path strategies. The findings indicated that the overtaking car's performance remained largely stable when a driver opts for overtake paths against the crosswind direction (i.e
Makhija, JaiSoares, Renan F.
With the increasing prevalence of electric vehicles (EVs), decreasing vehicle drag is of upmost importance, as range is a primary consideration for customers and has a direct bearing on the cost of the vehicle. While the relationship between drag and range is well understood, there exists a discrepancy between the label range and the real-world range experienced by customers. One of the factors influencing the difference is the ambient wind condition that modifies the resultant air speed and yaw angle, which is typically minimized during SAE coast-down testing. The following study implements a singular wind-averaged drag (WAD) coefficient which is derived from a 3-point yaw curve to show the impact of yaw as compared to the zero-yaw condition. This leads to an interesting dilemma for the vehicle aerodynamicist: whether to optimize the vehicle's exterior shape for low wind (zero yaw) conditions or for real-world conditions where the ambient wind generally produces a few degrees of yaw
Kaminski, MeghanD'Hooge, AndrewBorton, Zackery
This paper presents transient, complex, moving mesh, 3-D CFD analysis of an intebrake lubrication oil circuit for predicting flow performance. Intebrake is a mechanism for improving braking performance during over speeding conditions. The mechanism briefly opens the exhaust valve at the end of a compression stroke with a small valve lift and releases the compressed gases, thereby helping in quick application of the brake. There is no fueling during the process and hence, no combustion induced pressure rise which helps in quick application of the brake. During the intebrake operation, opening of the exhaust valve is achieved by using a complex lube oil circuit inside the exhaust rocker lever. The intebrake lube oil circuit consists of various spring-operated valves with micro-sized clearances, high oil pressure generation up to ~ 250 bar, 3-D movement of the mechanism components, and it is a transient operation. The 3-D movement consists of simultaneous rotational and translational
Tawar, Ranjit RamchandraPasunurthi, Shyam SundarBedekar, SanjeevRanganathan, Raj
The drive unit, primarily consisting of an electric motor and a gearbox, needs to be cooled and lubricated for its long life and efficient performance. In an extreme drive cycle condition, the pickup tube to the pump may get exposed to air, leading to a substantial loss in line pressure and a drop in oil flow rate to the subsystems. An advanced Computational Fluid Dynamics (CFD) simulation can provide insights into the oil delivery system and help in improving the oil sump design, optimizing the position of the pickup tube to the pump and oil delivery lines. The current study employs a Volume of Fluid (VOF) based multiphase model implemented in a commercial CFD solver, Simerics-MP+. The drive unit lubrication system considered in the study consists of a gerotor pump, the entire oil delivery lines to the two subsystems and the drive unit casing. A multiphase simulation of the system with transient operation of the pump is computationally expensive. Therefore, a new methodology is
Joe, Erin SamSchlautman, JeffManne, Venkata Harish BabuSrinivasan, ChiranthPasunurthi, Shyam Sundar
The efficient operation of electric vehicles (EVs) heavily relies on the proper lubrication of the E-drive unit components, particularly the transmission gears and bearings. Improper oil supply can lead to mechanical failures, while excessive oil can increase power loss due to churning. This study focuses on utilizing Computational Fluid Dynamics (CFD) simulations to analyze the impact of drive speed, oil level, and temperature on gear churning loss in E-drive units. The research also investigates the influence of a baffle plate on power loss and oil splash characteristics. The simulations, conducted using the volume of fluid (VOF) method in Simerics-MP+, consistently illustrate a reduction in power loss with rising oil temperature and reveal decreased gear churning loss with a baffle plate, especially under high-speed conditions, highlighting its potential for enhancing energy efficiency in EVs. Additionally, post-processing analysis of oil splash patterns sheds light on the
Kumar, P. MadhanMotin, AbdulPandey, AshutoshGanamet, AlainMaiti, DipakGao, HaiyangRanganathan, Raj
The U.S. DRIVE Electrical and Electronics Technical Team has set a goal for 2025 to achieve a power density of 33 kW/L for electric vehicle (EV) motors [1]. The increase in motor power density is highly dependent on effective thermal management within the system, making active cooling techniques like oil-jet impingement essential for continued advancements. Due to the time and expense of physical experimentation, numerical simulations have become a preferred method for design testing and optimization. These simulations often simplify the motor-winding surface into a smooth cylinder, overlooking the actual corrugated surface due to windings, thus reducing computational resources and mesh complexity. However, the coil's corrugated surface affects flow turbulence and heat transfer rates. This study utilizes three-dimensional Computational Fluid Dynamics (CFD) simulations to investigate the impingement-cooling of an Automatic Transmission Fluid (ATF) jet on a corrugated surface that
Mutyal, Jayesh RameshHaghnegahdar, AhmadGurunadhan, MohanaKonangi, SantoshChamphekar, Omkar
In the automotive industry, it is essential to consider not only how well specialty materials perform and are formulated, but also how efficiently and economically they can be applied during manufacturing. This becomes especially important during the early stages of development to prevent issues when these materials are used in new designs by automotive suppliers or manufacturers. With the rapid growth of electric vehicles (EVs), new materials are being used more frequently, and these materials may not have been as thoroughly tested as those used in traditional internal combustion engine (ICE) vehicles. Therefore, it is crucial to ensure that these materials can be applied correctly and efficiently from the start. One way to speed up the development process is through Computational Fluid Dynamics (CFD) modeling. CFD helps predict how materials will behave when dispensed, which is essential for developing the right equipment and conditions for applying these materials. Working with
Kenney, J. AndyDelgado, RobertoHossain, ArifNg, Sze-SzeThomas, RyanChyasnavichyus, MariusTsang, Chi-WeiHwang, MargaretWu, LanceDietsche, LauraMcmichael, JonathanRaines, KevinNelson, Grant
The vehicle wake region is of high importance when analyzing the aerodynamic performance of a vehicle. It is characterized by turbulent separated flow and large low-pressure regions that contribute significantly to drag. In some cases, the wake region can oscillate between different modes which can pose an engineering challenge during vehicle development. Vehicles that exhibit bimodal wake behavior need to have their drag values recorded over a sufficient time period to take into account the low frequency shift in drag signal, therefore, simulating such vehicle configurations in CFD could consume substantial CPU hours resulting in an expensive and inefficient vehicle design iterations process. As an alternative approach to running simulations for long periods of time, the impact of adding artificial turbulence to the inlet on wake behavior and its potential impact on reduced runtime for design process is investigated in this study. By adding turbulence to the upstream flow, the wake
DeMeo, MichaelParenti, GuidoMartinez Navarro, AlejandroShock, RichardFougere, NicolasRazi, PooyanOliveira, DaniloLindsey, CraigYu, ChenxingBreglia Sales, Flavio
This paper introduces a new approach for measuring changes in drag force across different vehicle configurations using an on-road testing technique. The method involves fixing the vehicle’s power across configurations and then measuring the resulting speed differences. A detailed formulation is provided on how these speed variations can be used to calculate the change in drag force for each configuration. The OBD II port is used to access and record additional data necessary for the calculations. The method is applied to both a passenger car and a commercial van to evaluate drag changes for different vehicle add-ons. A roof sign was installed at various positions along the roof of the vehicles to assess drag increases, while novel rear appendages were fitted to both vehicles to evaluate the resulting drag reductions. Detailed CFD simulations were performed on the road-tested configurations to compare the simulated drag changes with those measured on the road. Excellent agreement was
Connolly, Michael GerardIvankovic, AlojzO'Rourke, Malachy J.
Diesel combustion is a highly heterogeneous process in which the fuel must undergo several sub-processes after injection in order to release its heat through combustion. Prior to evaporation, computational fluid dynamic (CFD) simulations track the injected fuel mass using a Lagrangian frame of reference to determine the pathlines of the liquid fuel in the gaseous environment. However, after evaporation, when the fuel mass becomes part of the working fluid, it is no longer tracked in a Lagrangian reference frame as it undergoes its mixing and combustion processes. To gain deeper insights into the diesel combustion process, a methodology is proposed to track the evolution of fuel mass packets while in the gaseous state attaining a Lagrangian-esque description of the fuel’s evolution. This is achieved using the commercially available capabilities in Convergent Science’s CFD package, without requiring user-defined functions. The methodology is applied to a heavy-duty diesel engine and
Gohn, JamesKumar, MohitGainey, BrianLawler, Benjamin
Lithium-ion batteries (LIBs) are critical components in electric vehicles (EVs) and renewable energy systems. However, conventional cooling techniques for LIBs often struggle to efficiently dissipate heat during fast charging and discharging, potentially compromising performance and safety. This study investigates the thermal performance of immersion cooling applied to an Electric Vehicle (EV) battery module comprised of NCA-chemistry-based cylindrical 21700 format Lithium-ion cells. The effectiveness of immersion cooling in reducing maximum cell temperature, temperature gradient, cell-to-cell temperature differential, and pressure drop within the battery module is evaluated on a detailed 3D model of a 360-cell immersion-cooled battery module that was developed, incorporating a well-established heat generation model based on theoretical analysis and experimental data to simulate the thermal characteristics of the battery system. The effects of the different fluid properties are first
Garcia, AntonioMicó, CarlosMarco-Gimeno, JavierElkourchi, Imad
Experimental studies of wind tunnel blockage for road vehicles have usually been conducted in model wind tunnels. Models have been made in a range of scales and tested in a working section of fixed size. More recently CFD studies of blockage have been undertaken, which allow a fixed vehicle size and the blockage is varied by changing the cross section of the flow domain. This has some inherent advantages. A very recent database of CFD derived drag and lift coefficients for different road vehicle shapes and simple bodies tested in a closed wall tunnel with a wide range of blockage ratios has become available and provides some additional insight into the blockage phenomenon. In this paper a process is developed to derive the parameters influencing wind tunnel blockage corrections from CFD data. These are shown to be reasonably effective for correcting the measured drag and lift coefficients at blockage ratios up to 10%.
Howell, JeffButcher, DanielGleason, Mark
In this paper, the topology and shape optimization of a vehicle Heating, Ventilation, and Air Conditioning (HVAC) system is presented. The CFD and optimization methodologies are implemented within AcuSolve™ software. The topology optimization algorithm computes the geometry, where the design domain is parameterized with a field of porosity design variables which indicates the material, fluid or solid, throughout the domain. The optimization is performed using the continuous adjoint approach by the Galerkin Least Squares solver on which the AcuSolve™ solver is based. The design is further improved by using shape optimization. To optimize the geometrical shape, a combination of smooth perturbations, in terms of so called morph shapes, are used to deform the geometrical shape in the optimization algorithm. To this end, a parameterization of the design space is done using a moderate number of design variables, each associated with a morph shape. The two optimization phases are connected by
Papadimitriou, DimitriosSandboge, Robert
The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been very difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the author and similarly to those studies uses the computational fluid dynamics analysis of three bodies that generate large wakes to examine the interference phenomena in solid wall wind tunnels and the effects that they have on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from 0.4% to 14% blockage enabling an approximation of free air conditions as a reference
Gleason, MarkRiegel, Eugen
As a distributed wire control brake system, the electro-mechanical brake (EMB) may face challenges due to the need to integrate the actuator in the limited space beside the wheel. During extended downhill braking, especially on wet roads with reduced adhesion, the EMB must operate at high intensity. The significant heat generated by friction can lead to thermal deformation of components, such as the lead screw, compromising braking stability. This paper focuses on pure electric light trucks and proposes a tandem composite braking method. This approach uses an eddy current retarder (ECR) or motor to provide basic braking torque, while the EMB supplies the dynamic portion of the braking torque, thereby alleviating the braking pressure on the EMB. First, a driver model, tire model, motor model, and braking models are developed based on the vehicle's longitudinal dynamics. In addition, the impact of various factors, such as rainfall intensity, road slope, ramp length and vehicle speed, on
Liu, WangZhang, YuXiao, HongbiaoShen, Leiming
The advancement of automotive industry demand compact size of HVAC with better cabin comfort. To achieve this, HVAC has to be optimized in all the aspects such as in shape & size, thermal comfort as well as in noise comfort. from an HVAC perspective, aeroacoustics noise is more significant due to its intensity at higher speeds and frequencies. Since HVAC is mounted inside the cabin, noise can transfer directly inside cabin. To avoid this, noise reduction or noise controlling is of very important. This is possible with HVAC design and simulation at the initial level and acoustic prediction after the CFD/CAA analysis. The present paper describes the aeroacoustic simulation of one of the HVAC to predict the noise during face mode. For that, 1-D simulation has been done initially to find the porosity of heat exchangers and coupled with a CFD solver. STAR CCM+ software is used for the CFD analysis. Transient simulation is performed with compressible fluid using a moving mesh approach. To
Kame, ShubhamParayil, PaulsonGoel, Arunkumar
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