Browse Topic: Drag

Items (4,496)
This document describes a rigorous engineering test procedure that utilizes industry-accepted data collection and statistical analysis methods to determine the road load and to estimate the aerodynamic drag area of trucks and buses weighing more than 10000 pounds. The test procedure may be conducted on a test track or on a public road under controlled conditions and supported by extensive data collection and data analysis constraints. The estimated aerodynamic-drag-area result represents a single-speed and single-yaw-angle condition. Test results that do not rigorously follow the method described herein shall not be represented as an SAE J2978 result.
Truck and Bus Aerodynamics and Fuel Economy Committee
Aerodynamic interactions between two 30%-scale passenger vehicles in close proximity were examined experimentally in a large wind tunnel, with a focus on longitudinal separations up to two vehicle lengths, lateral separations up to one lane width, and combinations thereof. Part 1 of this paper described the longitudinal following (platooning) configurations of these results, while this paper concentrates on adjacent-lane influences and lateral-offset effects when platooning at a single separation distance. Test models were based on the DrivAer and Aero-SUV open-access geometries, each with slant-back (Notchback or Fastback) and square-back (Estateback) variants. This provided four distinct model pairings, not all of which were tested in each positional arrangement. Adjacent-lane results matched the trends from a smaller-scale study in a different wind tunnel using the same geometry pair, with small-but-distinct differences attributed to different blockage ratios in the two wind-tunnel
McAuliffe, BrianGhorbanishohrat, Faegheh
When driving in traffic, the wakes of leading vehicles reduce the wind speed experienced by a following vehicle, lowering its drag relative to isolated driving. These wake effects can persist to large inter-vehicle distances, on the order of hundreds of meters, while lateral convection due to cross winds can influence vehicles in adjacent lanes. Wind tunnel testing was conducted at 30% scale for light- and heavy-duty-vehicle models in a large wind tunnel with a traffic-wake simulation system, expanding upon a previous study that examined only heavy vehicles. Three variants of the DrivAer model, four variants of the AeroSUV model, and three variants of a zero-emission heavy-duty-truck model were tested with a range of simulated wake conditions that varied the type, forward distance, and lane position of the wake-source vehicle(s), for a range of yaw angles up to 11°. Results show drag reductions of up to about 10% for the heavy-duty-truck model, and up to about 20% for the passenger
McAuliffe, BrianGhorbanishohrat, FaeghehBarber, Hali
Open wheel race cars present a challenge to the aerodynamic designer because of the numerous wakes and vortices created by the various body components. The present study follows the development of a high-downforce race car and investigates possible vortex manipulations to increase its aerodynamic efficiency. The tools used for this study involved computational fluid dynamics and small-scale wind tunnel testing. Once the basic geometry of the racecar was finalized, cost effective measures were tested to improve its downforce to drag ratio. As an example, by fine tuning the position of different body components, such as the rear wing location relative to the underfloor diffuser exit, vehicle’s aerodynamic performance can be modified. The results of both the wind tunnel and the computational investigations indicated that such simple modifications can positively improve the race-car downforce to drag ratio. Also, once the baseline vehicle’s geometry was frozen and observing that the
Okpysh, ChristianKatz, JosephShute, Robin
The front wing of a Formula 1 car is one of the most important aerodynamic components in design development. Particularly, as it is the first to interact with the upcoming airflow, the aerodynamic flow structures generated will have a strong interaction with the remainder of the car’s components. In 2026, the Fédération Internationale de l’Automobile will introduce new regulations that incorporate new aerodynamic philosophies for the front wing, including active aerodynamics. This paper presents a design methodology study for the development of a Formula 1 2026 front wing, compliant with Issue 9 of the technical regulations. A computational-based, structured optimisation series was conducted to enhance the aerodynamic performance of a front wing concept with a focus on improving downforce, maximising efficiency, and enhancing trailing flow for the remainder of the car. The final front wing concept at 40%, running at 30 m/s, generated 189 N of downforce and 19 N of drag. Active
Jacoulot, SantiagoSoares, Renan F.Marshall, David W.
This paper presents a novel approach to modelling and analyzing a 315/80R22.5 sized truck tire running over dry and snow-covered surfaces. The tire is modelled using Finite Element Method (FEM) in ESI Virtual Performance Solutions (VPS) software. The tire model consists of various parts representing the tread, under tread, carcass, sidewalls and beads in addition to the rim. The tire model is then verified in both static and dynamic domains against experimental data. The experimental results were conducted over a dry surface at a high-speed test track in Hällered, Sweden, at a constant travelling speed of 80 km/h, and a constant vertical load of 26 kN with sensors depicting both temperature and inflation pressure changes throughout a 40-minute run. A tire temperature model is developed, and the simulation results are correlated with the measured temperature of the tested tires. In addition, the rolling resistance variation with speed, temperature and inflation pressure is predicted and
Opatha, DillonOijer, FredrikEl-Sayegh, ZeinabEl-Gindy, Moustafa
This paper investigates the performance of a computational radial passenger car tire over winter road sand at different operating conditions. This study seeks to address gaps in literature by using both an experimental direct shear-strength test and then validating the same test in a Finite Element Analysis (FEA) software called Virtual Performance Solution (VPS) using a Smoothed-Particle Hydrodynamic (SPH) technique to model a winter road sand. The simulated sand was measured against physical sand data ensuring validation of the density, internal friction angle and cohesion. Once the sand was validated against physical testing data the sand was layered atop an icy road surface to understand the influence sand has on tractive effort and rolling resistance performance. With modelled and validated winter road sand and a Continental CrossContact LX Sport tire size 235/55R19 testing conditions were set up. The tire-sand interaction was simulated using a node-to-segment contact algorithm
Fenton, ErinEl-Sayegh, Zeinab
The Electro-Mechanical Brake (EMB) system is a novel type of brake by wire systems with independently controllable characteristics. This system aids in the decoupling analysis of the vehicle and actuator dynamics, thereby improving the accuracy of parameter identification. Therefore, this paper proposes an innovative parameter identification method for vehicle parameters and longitudinal tire model parameters, based on the characteristics of the EMB system and onboard sensors. First, based on the wind resistance and rolling resistance coefficients obtained from the vehicle coasting conditions, a decoupled constant clamping force sequence braking condition for the front and rear axles is designed by integrating the characteristics of the EMB actuator and vehicle dynamics. This approach enables the identification of vehicle and nonlinear longitudinal tire model parameters, significantly improving the accuracy of parameter identification. Next, considering the nonlinear characteristics of
Huang, JiayiCheng, YulinZhuo, GuirongLe, QiaoWei, WeiShu, Qiang
MSIL (Maruti Suzuki India Limited), India’s leading automotive manufacturer, offers a diverse range of SUVs (Sports Utility Vehicles) in its portfolio. Traditionally, SUVs are associated with an assertive stance and a commanding road presence; however, this bold design language often compromises aerodynamic drag performance. Over the past decade, demand for this segment has surged, while CAFE (Corporate Average Fuel Economy) regulations have become increasingly stringent. To address this growing market need, MSIL conceptualized a new SUV - Victoris - targeted to deliver best-in-class aerodynamic efficiency in MSIL SUV portfolio. This paper details the aerodynamic development process using CFD (Computational Fluid Dynamics) and full-scale WTT (Wind Tunnel Testing). Initially, the aggressive styling of Victoris negatively impacted drag performance. Strategic exterior surface refinements and integration of aero components enabled recovery of aerodynamic efficiency. Key interventions
Dey, SukantaSingh, ShekharKumar, ChandanAlphonse, Felix Regin
As automotive aerodynamic testing facilities evolve to capture more real-world behavior, updating the correlation between old and new technologies is essential. Recently, the three-member consortium of the United States Council for Automotive Research (USCAR) - General Motors, Ford Motor Company, and FCA US LLC - transitioned from full-size static ground plane facilities to 5-belt moving ground plane wind tunnel facilities. The primary objective of this study was to update the correlation data sets to maintain consistent and robust data sharing among companies, which is the cornerstone of USCAR efforts. To achieve this, a set of updated correlation data sets were calculated to replace the original correlation study results from 2008. Additionally, the methodology for applying correlation equations was revised from using averaged wind tunnel data to employing direct wind tunnel-to-wind tunnel correlation equations. In a two-phase correlation effort conducted in 2022 and 2025, the three
Nastov, AlexanderLounsberry, ToddMadin, TrevorLangmeyer, GregoryFadler, GregorySkinner, ShaunHorton, Damien
This study presents a comparative assessment of two machine learning approaches for predicting aerodynamic drag coefficients (Cd) in automotive vehicle designs using data derived from computational fluid dynamics (CFD) simulations. The first approach employs traditional regression models trained on structured parametric data generated through controlled geometric variations, while the second approach integrates unstructured point-cloud geometry with structured metadata using a multi-modal deep learning framework. Both methods are evaluated within their respective contexts to understand their strengths, limitations and potential roles in automotive aerodynamic workflows. Rather than identifying a single best approach, the study highlights how these methods address different design needs and resource constraints, providing insights for future hybrid strategies that combine interpretability with geometric sensitivity. The work aims to establish a foundation for data-driven aerodynamic
Kumar, GauravKhanna, Susheel
Since air drag is proportional to the square of the speed, it is expected that reducing air drag will significantly improve fuel efficiency for on-highway trucks and buses, which are often driven at high speeds. Therefore, the purpose of this study is to propose an optimization method for vehicle shape to drastically reduce aerodynamic drag in heavy-duty vehicles. Using NSGA-II, one of a genetic algorithm, the overall vehicle shape was optimized with drag coefficient (CD) and lift coefficient (CL) values as objective functions and design variables as parameters in a total of 13 locations. Among the Pareto solutions, an 86% reduction in CD was achieved compared to the base shape when the CD value was the lowest. Since the CL value remains low with this shape, it can be seen that driving stability does not deteriorate. Among the design variables in optimization, it was confirmed that the corner radius of the vehicle side was particularly effective in reducing the CD value. In addition
Kawano, Daisuke
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, DavidMynderse, James
Moving ground wind tunnels offer a more accurate test environment for ground vehicle drag coefficient measurement due to their highly realistic representation of the boundary layer phenomenon. However, historically most vehicles have been tested on static ground wind tunnels. As a result, the measured drag coefficient of these vehicles may not be sufficiently realistic for certification purposes. Therefore, it is valuable to build statistical models to estimate moving ground wind tunnel drag coefficient by using information from a static ground wind tunnel and other relevant vehicle characteristics such as presence of aerodynamic devices (spoilers, air dams, etc.). However, to build accurate statistical models, appropriate predictive features must be identified as a first step. In this paper, an aerodynamic feature selection study has been conducted to identify vehicle characteristics that contribute to drag coefficient estimation discrepancies between a static- and a moving ground
Singh, YuvrajJayakumar, AdithyaRizzoni, Giorgio
Thermal and lubrication management is critical for the performance characteristics of Electric Drive Units (EDUs) in electrified powertrains. Accurate assessment of lubrication flow, particularly in terms of wetting behavior and churning losses, is essential for optimizing EDU performance across various driving conditions. This study presents a comprehensive numerical investigation of lubrication flow behavior within an EDU using an advanced Smoothed Particle Hydrodynamics (SPH) method. The mesh-free SPH approach provides significant advantages in modeling intricate oil dynamics, such as oil splashing, and the behavior of oil in contact with rotating components. The primary focus of this study is to investigate the phenomena of oil splashing, wetting behavior characterized by the Wetting Fraction(WF), and churning losses within the gearbox environment. Key flow characteristics such as oil distribution, particle trajectories, torque resistance due to fluid drag, and oil volume fraction
Chintala, ParameshInada, JorgeFlores Solano, Cesar AlfonsoGingade, Suresh
This study presents a simulation method for reproducing slush accumulation on underbody components, with a particular focus on the floor undercover, during vehicle operation on slush-covered roads. As electrified vehicles become increasingly important in the pursuit of carbon neutrality, the adoption of aerodynamic undercovers to improve driving range has accelerated. However, these components are exposed to various environmental stresses, including water, chipping, and especially snow and slush, which can lead to damage and performance degradation. While previous research has addressed water and chipping stresses through simulation, studies on slush-induced stress have been limited. To address this gap, the Moving Particle Semi-implicit (MPS) method was applied, incorporating a power-law model to represent the non-Newtonian flow characteristics of slush. Parameter identification was conducted through steel ball drop tests and tire scattering tests, ensuring both qualitative and
Matsuura, TadashiAnnen, TeruyukiHarada, TakeyukiUeno, ShigekiAsai, MikioWatanabe, Haruyuki
In this paper, the effects of aerodynamic interactions on the drag of a longitudinally-arranged two-vehicle system are examined by considering the influence of separation distance, cross winds, vehicle size and shape. Testing was undertaken at 30% scale in a large wind tunnel with road-representative freestream turbulence. Separation distances of 0.5, 1.0, and 2.0 vehicle lengths (L) were examined over a range of yaw angles between ±15°. A highlight of the current study is the characterization of platoon drag-reduction benefits for different sizes and shapes of the lead and follower models, by using a DrivAer model and an Aero-SUV model, each with slant-back (Notchback or Fastback) and square-back (Estateback) variants, providing four distinct model pairings. Drag reduction for the lead model appears to be affected mainly by the size of the follower model, while the follower model shows a much greater sensitivity to shape of the lead model. Larger drag reductions were observed at most
McAuliffe, BrianGhorbanishohrat, Faegheh
Wind-tunnel tests were conducted using a 30%-scale DrivAer model, in estateback and notchback rear-geometry configurations, to investigate aerodynamic performance changes associated with snow and ice buildup on passenger vehicles. Around 20 snow/ice accumulation patterns were tested, at a Reynolds number of 2.8 × 106 based on model wheelbase, for each of the notchback and estateback variants. 5 additional patterns were tested on the estateback with roof-rack support bars. Snow accumulation was modelled with foam, while ice accumulation was simulated with aluminum tape hand-formed to the desired shape. A simulated full-scale snow thickness of 58 mm on the hood, roof and trunk increased the wind-averaged drag coefficient by 16% for both model variants. With 90 mm of snow, the drag of the estateback variant increased by 19%. Drag changes increased with, but were not proportional to, snow thickness. Chamfered front and rear edges, representing windblown shapes, reduced the drag penalty
de Souza, FenellaMcAuliffe, Brian
Electrification is rapidly entering all vehicle classes, including light- and heavy-duty trucks designed for heavy towing capabilities. Still, the quantitative impact of towing on battery-electric vehicle (BEV) energy use and range remains under-characterized. We conducted controlled towing tests with a Ford F-150 Lightning using two trailers of different sizes and varying payloads to isolate aerodynamic and mass effects and to span the full range of towable payloads within the vehicle’s rated capacity. The vehicle was instrumented at the CAN bus level, capturing motor power, torque, speed, and related internal signals from different control modules. On-road testing consisted of repeated back-and-forth passes on level, straight road segments at set speeds focusing on highway operation, where aerodynamic drag is stronger and real-world towing use cases occur. From these data, we extracted road load equations and dynamometer coefficients for each trailer combination, then reproduced
Timermans Ladero, Inigo
This study estimates the impact on driving energy of differences in aerodynamic characteristics for yaw angle from natural wind during North American Highway mode driving. A previous study [1] clarified the potential to estimate the fuel consumption impact of natural wind by integrating the drag coefficient yaw characteristics and yaw angle occurrence probability. The natural wind was measured on a vehicle while driving a representative North American Highway test course [2]. Driving energy is predicted from the obtained yaw probability and the drag coefficient yaw sweep data in a wind tunnel. Measurements were conducted every weekday for 8 hours in 2023, covering 70% of the traffic volume. The validity of the measurement period was evaluated by the deviation from the annual average of wind direction and speed. Since yaw probability varies depending on the road environment, it is necessary to weigh the road environment type probability when calculating the driving energy. The
Onishi, YasuyukiNucera, FortunatoNichols, LarryMetka, Matt
A research team developed a smart strake system that dynamically adapts to flight conditions, showing a promising drag reduction in the wind tunnel with respect to passive strakes. This approach has the potential to save airlines hundreds of kilograms of fuel per flight. University of Washington Department of Aeronautics & Astronautics (A&A), Seattle, WA For decades, aircraft have carried a fundamental compromise between their engines and wing flow interactions by using strakes. These are small fins attached at the sides of engine nacelles that generate helpful vortices during takeoff and landing that boost lift and avoid stall, but create unwanted drag during cruise flight. Now, seven William E. Boeing Department of Aeronautics & Astronautics (A&A) undergraduates have advanced a solution that improves this trade-off, achieving up to 33 percent drag reduction, on the limited tested conditions, during cruise while maintaining critical safety benefits at high angles of attack. The team
As motorsports evolve with technological advancements, aerodynamics plays a crucial role in race car performance. This review examines the impact of aerodynamics on car design and its evolution, presenting a statistical analysis of existing sports cars. We highlight key performance factors like engine power, top speed, drag, and weight. The key contribution of this review is the critical synthesis of the safety-performance trade-off, especially linking aerodynamic optimizations to the stability and safety of sports cars. Furthermore, we explore mathematical modeling of vehicle aerodynamics to enhance the understanding of performance aspects such as top speed, acceleration, cornering, and braking. This article also provides a review of recent active and passive aerodynamic devices to assist researchers in selecting designs, with an emphasis on the importance of ground effect. We also present recent numerical methods, particularly 3D simulations. The statistical data can help researchers
Eftekhari, HesamAl-Obaidi, Abdulkareem Sh. MahdiEftekhari, Shahrooz
The current work analyzes the effect of time-step size on the predictive capability and computational cost of the Sliding Mesh (SM) method for modeling flows around the rotating wheels of a mass-production luxury sport utility vehicle (SUV). Two unsteady turbulence models [Unsteady Reynolds-Averaged Navier–Stokes (URANS) and Delayed Detached Eddy Simulations (DDES)] were tested using time-step sizes ranging from the current recommended time-step size of 1 degree of rotation per time-step (1 D/TS) up to 50 degrees of rotation per time-step (50 D/TS). The flow field predictions compare favorably to the 1 D/TS case for a time-step size as large as 5 D/TS. Using this time-step size leads to a reduction in computational cost of approximately 80% for both unsteady methods. At a time-step of 5 D/TS, the computational cost of the SM method is comparable to the more commonly used Moving Reference Frame (MRF) method. However, drag and flow field predictions by the SM method at this larger time
Struk, MichaelAultman, MatthewDisotell, KevinDuan, LianBianco, AntonelloMetka, MatthewKhasdeo, Nitin
Flight vehicles operating in low-speed environments face significant aerodynamic challenges due to weak laminar boundary layers, which lead to early flow separation, reduced lift, and increased pressure drag. Airfoils often experience laminar separation bubbles and abrupt stall, making their performance unstable and difficult to predict. This paper aims to address the low-speed aerodynamic parameter analysis using passive flow control techniques on modified NACA 0021 airfoil profile. The novelty of this research method lies in the integration of dimple-based passive flow control structures on the upper surface of a NACA 0021 airfoil specifically designed to delay flow separation and enhance low-speed aerodynamic performance. Unlike most previous studies that focus on conventional vortex generators or active flow control methods, this work uniquely demonstrates that strategically dimple on the airfoil surface modifications significantly improves the lift characteristics. The methodology
Lakshmanan, D.Raman, Senthil Kumar BellaSivakumar, AravinthPillai, Balaji Shanmuga
The wetted surface of a wing induces a three-dimensional pressure distribution onto the surrounding flow field that generates lift. In a similar way, the wetted surface of an aircraft generates parasite drag. Computational fluid dynamics mimics this process by constructing a surface mesh as a grid that recreates the outer mold line (OML) or wetted surface of a wing or aircraft, and used as a geometric reference for calculating the lift and parasite drag. Once the lift and drag are obtained using these physics-based wetted surfaces as geometry references, the legacy lift and drag coefficients are calculated by resorting to the planform area of the wing, and not their aforementioned wetted surfaces. This re-referencing that results from using a planform area instead of a wetted surface results in an overestimation of the lift and drag coefficients that are devoid of a physical meaning and yield misleading results when used to compare the lift or drag of different aircraft. This paper
Burgers, Phillip
With increased deterioration of road conditions worldwide, automotive OEMs face significant challenges in ensuring the durability of structural components. The tyre being the primary point of contact with the road is expected to endure harshest of impacts while maintaining the other performance functions such as Ride & Handling, Rolling resistance, Braking. Thus, it is considered as the most challenging component in terms of design optimization for durability. The current development method relies on physical testing of initial samples, followed by iterative construction changes to meet durability requirements, often giving trade-off in Ride & Handling performance. To overcome these challenges, a frugal simulation-based methodology has been developed for predicting tyre curb impact durability before vehicle-level testing so that corrective action can be taken during the design stage.
Sundaramoorthy, RagasruobanLenka, Visweswara
Reducing drag forces and minimizing the rear wake region are the main goals of evaluating exterior aerodynamic performance in automobiles. Various literature and experiments shows that the overall fuel computations of the road vehicle improves significantly with the reduction in aerodynamic drag force. In the road vehicle major components of the drag is due the imbalance in pressure between front and rear of the vehicle. At high vehicle speed, aerodynamic drag is responsible for approximately 30 to 40% of the energy consumption of the vehicle. In the recent year, cost of high-performance computing (HPC) has reduced significantly, which helped computational fluid dynamics (CFD) is an affordable tool to the automotive industry for evaluating aerodynamic performance of the vehicle during developing phase. The vehicles aerodynamic performance is greatly impacted by the dynamic environmental conditions it encounters in the real world. Such environmental conditions are difficult to replicate
Chalipat, SujitBiswas, KundanTare, Kedar
With increasing demand for improving the vehicle Ride and Handling (R&H) performance, the synergy between vehicle subsystems such as suspension, chassis, brakes & tyres play a major role towards it. In this regard, the interaction between wheel rim width and tyre performance characteristics is a key focus area in vehicle development process. Detailed research is being conducted worldwide to understand their dynamics of interaction and based on the tested data, vehicle manufacturers make the design selection. In this context, the proposed study aims to provide a in-depth analysis of how variations in wheel rim width affect key tyre performance parameters such as lateral force characteristics, damping property, tyre footprint, and pinch cut resistance. Also, the subsequent influence on vehicle-level performance parameters such as R&H, braking, steering, and durability is captured. Based on these analysis, appropriate wheel rim size selection is done which is most optimal for the project
Singh, Ram KrishnanPaua, KetanSundaramoorthy, RagasruobanLenka, Visweswaraahire, ManojAdiga, Ganesh N
Tyre rolling resistance is a fundamental parameter in automotive engineering, directly impacting vehicle fuel efficiency and overall performance. The Rolling Resistance Coefficient (RRC) is influenced by tyre construction, material properties, and operational conditions such as inflation pressure, vehicle speed, ambient temperature, and road surface roughness. This study investigates the influence of critical parameters—including test speed, inflation pressure, temperature on the rolling resistance of tyres of various sizes. While previous research has predominantly focused on radial tyres, this paper extends the analysis to include bias-ply tyres. The findings aim to offer valuable insights for policymakers and researchers by examining the behavior of bias tyres under real-world conditions. The results will be particularly beneficial for vehicle and steering system designers, offering data-driven insights to support future tyre and vehicle development. Additionally, the study presents
Joshi, AmolBelavadi Venkataramaiah, ShamsundaraKhairatkar, Vyankatesh
The Mahindra XUV 3XO is a compact SUV, the first-generation of which was introduced in 2018. This paper explores some of the challenges entailed in developing the subsequent generation of this successful product, maintaining exterior design cues while at the same time improving its aerodynamic efficiency. A development approach is outlined that made use of both CFD simulation and Coastdown testing at MSPT (Mahindra SUV proving track). Drag coefficient improvement of 40 counts (1 count = 0.001 Cd) can be obtained for the best vehicle exterior configuration by paying particular attention to: AGS development to limit the drag due to cooling airflow into the engine compartment Front wheel deflector optimization Mid underbody cover development (beside the LH & RH side skirting) Wheel Rim optimization In this paper we have analyzed the impact of these design changes on the aerodynamic flow field, Pressure plots and consequently drag development over the vehicle length is highlighted. An
Vihan, Nikhil
In the automotive industry, external aerodynamic evaluations in digital environments are commonly conducted using simplified, large box tunnels with vehicle being static. These approaches are computationally efficient and ensure faster turnaround time. To closely replicate physical wind tunnel testing or real-world conditions, these simulations are often augmented with moving ground and rolling tire configurations. While such setups provide valuable directional feedback for aerodynamic drag improvements, they frequently exhibit significant discrepancies when compared to physical wind tunnel test data. It is observed that key factors such as wind tunnel blockage effects, boundary layer suctions, when not properly accounted for, distort the local flow field dynamics and introduce errors in the simulations. With OEMs aiming to accelerate time-to-market for new vehicle launches, many aspire to minimize reliance on physical testing and maximize use of digital methods for design sign-off
Sharma, Sandeep KumarChalipat, SujitMaiyya, Sandeep
The Ro-dip Cathodic Electrodeposition (CED) process is new technology used by automotive manufacturers for higher quality corrosion protection in new generation automobiles. This process involves multiple 360-degree rotation of automotive body-in-white (BIW) which exert higher hydrostatic pressure and drag forces on large surface panels of BIW like hood. For maintaining consistent gaps and flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel hood panel while undergoing through this CED process. This study investigates the enhancement of hood structure supports through strategic optimization of support rod placement and quantity within the Ro-dip CED paint shop system. This Paper underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional
Tile, VikrantUnadkat, SiddharthAskari, HasanJadhav, Devidas
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating subsystems such as the high voltage battery (HVB), Electric powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant to cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and EPT thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, AbhijeetKumar, DipeshGummadi, GopakishoreKhan, ParvejThiyagarajan, RajeshPandey, RishabhS, AnanthAnugu, AnilMulamalla, SarveshwarGangwar, Adarsh
Transportation sector in India accounts for 12% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions intensity of its GDP by 40% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each
Gijare, SumantKarthick, K.Juttu, SimhachalamThipse, Sukrut S.A, JothikumarJ, Frederick RoystonSR, SubasreeG, HariniM, Senthil Kumar
In this work, the complex wake flow from a double-slanted Ahmed body with an upper slant of α = 25° and a standard single-slanted Ahmed body with a slant angle of 40° were used to evaluate vortex identification methods for automotive wake flows. Multiple three-dimensional (3D) vortex identification methods including Q−, λ 2−, Ω− criteria, and Liutex method and the two-dimensional (2D) Γ1− criterion were evaluated against the streamline topology as a pseudo-truth model. Of the 3D methods analyzed, none were found to produce wholly satisfactory results. The Q− and λ 2−criteria were plagued by high threshold sensitivity and a failure to separate shear from rotation which led to inconsistent identification of the weak, lower-rotation vortices. While the Ω−criterion was able to mitigate the issues related to threshold sensitivity and separation of shear and rotation by consistently identifying the weak vortices, the identified structure did not align well with the streamline topology
Aultman, MatthewDuan, Lian
The front wing is a critical component of a Formula 1 car, directly influencing aerodynamic efficiency and overall performance. This study focuses on optimizing the computational simulation process for a Formula 1 front wing, using the Imperial Front Wing (IFW) model as a benchmark. Computational Fluid Dynamics (CFD) simulations were for this study, with a particular emphasis on evaluating ground effect and aerodynamic drag characteristics. A higher ground height configuration of the IFW is evaluated in this study. The results, including aerodynamic coefficients and fluid flow visualizations, were compared with findings from previous literature to assess their accuracy and consistency. The study demonstrated strong alignment with theoretical expectations, validating the simulation approach. Additionally, this research lays the groundwork for further refinements in mesh optimization and simulation methodologies, contributing to more efficient aerodynamic analysis in high-performance
Victor, Gabriel Santos Barreto FreitasGonzalez, José Fernando PazAlves, Julio César LelisBuscariolo, Filipe Fabian
This study focuses on the multifunctional three-body high-speed unmanned boat model, and experimentally measures the roll attenuation characteristics under different draft conditions. It focuses on the influence of the initial roll angle on roll attenuation, and analyzes the change pattern of roll angle over time. Experimental results show that the model shows obvious self-oscillation period and amplitude attenuation. Based on the system identification theory and combined with improved genetic algorithms, a mathematical model used to simulate the roll attenuation motion of the boat model was constructed. The difference between experimental data and fitted values was further evaluated using identification software and verified with data at specific roll angles. In addition, the study also deeply analyzed the change trend of the roll moment coefficient with the initial roll angle. By comparing the experimental results of the three-mall boat and the catamaran, it was found that the three
Zhang, DiTong, WeiYu, QingzhuLiu, Bofei
Off-highway vehicles (OHVs) routinely navigate unstable and varied terrains—mud, sand, loose gravel, or uneven rock beds—causing increased rolling resistance, reduced traction, and high energy expenditure. Traditional rigid chassis systems lack the flexibility to adapt dynamically to changing surface conditions, leading to inefficiencies in vehicle stability, maneuverability, and fuel economy. This paper proposes an adaptive terrain morphing chassis (ATMC) that can actively modify its structural geometry in real-time using embedded sensors, hydraulic actuators, and soft robotic elements. Drawing inspiration from nature and recent advances in adaptive materials, the ATMC adjusts vehicle ground clearance, track width, and load distribution in response to terrain profile data, thereby optimizing fuel efficiency and performance. Key contributions include: A multi-sensor fusion system for real-time terrain classification Hydraulic actuators and morphing polymers for variable chassis
Vashisht, Shruti
Real Driving Emission (RDE) testing for motorcycles presents unique challenges due to the motorcycle’s lightweight construction, limited mounting space, and sensitivity to added mass and aerodynamic drag. Full-functional automotive Portable Emission Measurement Systems (PEMS), while highly accurate, are often impractical for two-wheelers as their weight and size can alter driving resistances, fuel consumption, and emission profiles, but also complicate installation and probably effect the drivability of the vehicle. To address these limitations, lightweight alternatives such as Mini-PEMS and ultralightweight alternatives such as Sensor-based Emission Measurement Systems (SEMS) offer compact, low-power solutions tailored for small vehicles. SEMS are typically equipped with lower cost sensors and low-tech gas conditioning systems compared to PEMS. Due to this these systems may not meet regulatory homologation requirements. Nevertheless, they provide justifiable accuracy for many real
Schurl, SebastianLienerth, PeterJaps, LeonidSchroeder, MatthiasSchmidt, StephanKirchberger, Roland
India, being one of the largest automotive markets has considered various policies affecting fuel efficiency to curb vehicle carbon emissions. In a typical light-duty vehicle (LDV), around 20% of the fuel's energy is used to power the wheels and overcome aerodynamic drag resistance. Aerodynamic drag resistance, influenced by the projected surface area, cooling drag and velocity refers to the resistive force encountered by the vehicle. Furthermore, cooling drag resistance is determined by the effective cooling system architecture and aerodynamic design of the front-end module (FEM), which has major impact on the vehicle's performance and ram curve. In the pursuit of enhancing cooling system architecture, this paper investigates thermal performance and structural integrity of using common fins for both the condenser and radiator to improve the inlet aerodynamic performance which lowers cooling fan power consumption. Preliminary results show a 12% notable reduction in motor power
K, MuthukrishnanVijayaraj, Jayanth MuraliN, AswinNarashimagounder, ThailappanMahobia, Tanmay
System-level design decisions in Formula SAE (FSAE) vehicles drive all downstream subsystem designs, yet these decisions are often based on historical precedent or anecdotal evidence rather than rigorous analysis. This work presents a simulation-driven methodology to support data-informed decisions early in the design process, specifically examining how overall vehicle parameters—such as engine power, vehicle mass, aerodynamic drag and lift, wheelbase, and track width—influence performance in a representative FSAE endurance scenario. Two types of lap-time simulation tools were used in this study: OpenLAP, a point-mass simulator, and ChassisSim, a transient 3D vehicle dynamics simulator that incorporates suspension geometry, yaw response, weight transfer, and steering effects. Initial simulations with OpenLAP were used to rapidly identify trends and guide early design decisions, while ChassisSim was used for detailed sensitivity analyses and to validate system-level trade-offs in a more
Hernandez, Andy JoseBachman, John Christopher
As automotive manufacturers have tried to set themselves apart by reducing emissions, and increasing vehicle range/fuel economy by eliminating any energy loss from inefficiencies on the vehicle, the brake corners have been an area of interest to reduce off-brake torque to zero in all conditions. Caliper designers can revise some attributes like piston seal grooves, and pad retraction features to reduce drag, but even if a caliper is designed perfectly in all aspects, trying to measure it in a reliable and repeatable manner proves to be difficult. There are many ways to measure brake drag all with ranging complexity. Some of the simplest measurements are the most repeatable, but it excludes the majority of the vehicle inputs. The most vehicle representative testing requires the most complex equipment and comes with the most challenges. This paper will focus mainly on the different ways residual brake drag can be measured, the benefits and challenges to each of them, the problems trying
Retting, Joshua
Electro-mechanical braking (EMB) system has emerged as a potential candidate that serves the brake-by-wire technology. Several mechanisms are used to transmit the clamp force, where each has efficiency losses due to static friction and viscous damping. Compensating these losses is essential for accurate responses such that meeting the performance goal and improving the stopping distance of the EMB. Mathematical and empirical models are used to estimate these losses so that clamp force is accurately estimated and controlled. However, none of these models are capable of addressing the part-to-part variation or predicting the impact of other noise factors on these losses such as operating temperature and degradation. The purpose of this work is to online estimate the EMB coulomb friction by introducing an external torque command over a period of time while observing the system’s response. This approach continuously measures the coulomb friction while the system is in normal operation
Aljoaba, SharifRamakrishnan, RajaDobbs, Jeremy
Electric vehicles (EVs) require improved drag performance from wheel bearings to achieve a longer range. EVs are heavier and have higher torque output compared to internal combustion-powered vehicles. Due to the increased weight and torque of EVs, there will be higher loads at the bearing-to-knuckle joint. These increased loads may necessitate higher clamp loads to maintain joint integrity. However, higher clamp loads can lead to distortion or reduced roundness of the wheel bearing outer ring. Such distortion permanently increases drag and reduces bearing life. Therefore, after vehicle corner assembly with higher clamp loads, it is critical to minimize outer ring distortion during the initial assembly and throughout the bearing's lifespan. This paper will cover the design considerations for the wheel bearing outer ring to minimize distortion, utilizing Computer-Aided Engineering (CAE) analysis for various designs. A Design of Experiments (DOE) will be conducted to understand the
Mandhadi, Chaitanya ReddyCallaghan, KevinSutherlin, RobertLee, SeungpyoLee, YeonsikBovee, Benjamin
The recent advancements in vehicle powertrain and aerodynamics have led to an increase in the production of faster passenger cars, where high-speed driving scenarios demand equally efficient and safe braking systems to ensure the safety of both passengers and surrounding vehicles and pedestrians. At high speeds, aerodynamics can significantly impact overall vehicle braking performance due to the interaction between downforces and lift forces, which, in turn, affects the vehicle’s overall dynamic weight, directly contributing to the maximum attainable deceleration or braking force. Accordingly, the braking performance can be maximized by generating more downforce by means of rear spoilers, while taking into consideration their inevitable drag, which adds to the total vehicle motion resistance. Therefore, this proposed work aims to investigate the effectiveness of employing an active rear spoiler to enhance the vehicle’s braking performance, without introducing remarkable drag that could
Abidou, DiaaAbdellah, Ahmed HelmyHaggag, Salem
In recent years, there has been a significant rise in research focused on estimating the base pressure (Pb) characteristics of convergent–divergent nozzles with sudden expansion regions. This study explores the use of geometrical parameters as a control strategy for nozzles experiencing abrupt expansion at supersonic Mach numbers within an axisymmetric duct. It focuses on four distinct novel expansion duct configurations: square nozzle (SN), step square nozzle (SSN), curved nozzle (CN), and double curved nozzle (DCN). In this work, the high-speed compressible flow investigation is carried out numerically using control volume method on the nozzle with a fixed area ratio (AR) and L/D nozzle. Standard k-ε turbulence model is used in the analysis to access the recirculation region formed near the nozzle walls. The recirculation zone directly influences the Pb and shock cell. For NPR range from 2 to 10, SSN and CN shows an increase in Pb, which further increases the thrust and decreases the
Raj, R. JiniKumar, P. DeepakPanchksharayya, D. V.Kousik Kumaar, R.Praveen, N.
ABSTRACT The UH-60A slowed rotor test campaign carried out at the 40- by 80-Foot Wind Tunnel at the U.S. Air Force's National Full-Scale Aerodynamics Complex (NFAC) provided valuable information of a classical helicopter rotor blades operating at very high advance ratios. This paper aims to show the correlation of the RCAS and HOST comprehensive analysis (CA) tools with respect to several experimental campaign cases. Particularly the influence of the rotor aerodynamic performance as a function of the advance ratio and the collective angle is studied. The influence of the shank drag modeling is observed and its importance to obtain accurate results is highlighted. The RCAS and HOST simulations are capable of reproducing the rotor performance trends observed in the test campaign. Furthermore, the correlation of RCAS and HOST with respect to the measured rotor loads data is studied for the advance rations of 0.4, 0.5 and 0.7 at iso-thrust coefficient conditions. The aerodynamic loads and
Balmaseda Aguirre, MikelYeo, Hyeonsoo
ABSTRACT This study presents computational analyses of coaxial rotor hub flows and validation against experimental data obtained from the fifth Rotor Hub Flow Prediction Workshop. Experiments were conducted in a 12-inch diameter water tunnel at Pennsylvania State Applied Research Laboratory, employing tomographic particle-image velocimetry (Tomo-PIV) and precise hub drag measurements. Three CFD codes (UMD Mercury, CREATETM-AV Helios, and OVERFLOW) utilizing hybrid Reynolds-Averaged Navier-Stokes (RANS) / Large Eddy Simulation (LES) modeling based on Spalart–Allmaras turbulence model, were applied to replicate and analyze hub flows. Counter-rotating coaxial rotor hubs under free-air condition was simulated as the simplest case and the hub drags are compared between the three CFD codes. The full water tunnel configuration, consisting of two hubs, a fairing, and shafts, was also simulated and compared to experimental results, with a focus on hub drag, wake velocity fields, and turbulence
Deore, NealCoder, JamesSchmitz, SvenGosin, SamuelBaeder, JamesPremaratne, PavithraJain, RohitJung, Yong Su
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