3 rd European Hyperworks Technology Conference. Application of Results from CFD-Simulations on a Race Car

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1 3 rd European Hyperworks Technology Conference Application of Results from CFD-Simulations on a Race Car Ludwigsburg, November 3 rd 2009 Dipl.-Ing. René Henn, Dipl.-Ing. Leif Ickert Institut für Kraftfahrzeuge RWTH Aachen University # rh0140.ppt Slide No. 1

2 Overview Introduction Design of a CFRP Hood CFD-Simulations Wind Channel Tests Summary # rh0140.ppt Slide No. 2

At the same time new technologies should be proved under the extreme

3 Introduction Motivation We want to inspire young people for the automobile and to instruct young scientific engineers. At the same time new technologies should be proved under the extreme conditions of motorsport in further steps. (Univ.-Prof. Dr.-Ing. Stefan Gies) # rh0140.ppt Slide No. 3

Introduction Team and Tasks Tuning Akademie Ingolstadt Project leading Pereparation of the vehicle for races Technical improvements of the vehicle Contact to employees of the Audi AG RWTH

Drivers 2009: Application of the vehicle on the Nuerburgring Thomas Hanisch Stefan Gies Klaus Leinfelder Hans Keutmann Michael Kühne Team: Development engineers of the Tuning Akademie

4 Introduction Team and Tasks Tuning Akademie Ingolstadt Project leading Pereparation of the vehicle for races Technical improvements of the vehicle Contact to employees of the Audi AG RWTH Aachen University Development of innovative technologies for usage in the vehicle Teaching at the RWTH Aachen University within mini and master theses Organisation of races and exhibitions Drivers 2009: Application of the vehicle on the Nuerburgring Thomas Hanisch Stefan Gies Klaus Leinfelder Hans Keutmann Michael Kühne Team: Development engineers of the Tuning Akademie Scientific employees of the RWTH Aachen University Technicians of the ika Student assistants of the RWTH Aachen University Mini and master theses students of the RWTH Aachen University # rh0140.ppt Slide No. 4

5 Introduction From a Body-in-White to a Race Car Body-in-White Assembly Chassis assembly Drivetrain assembly Testing 2008 CFRP steel doors 1 st race 2008 Assembly of screens Optimisation of chassis Optimisation of aerodynamics Testing 2009 # rh0140.ppt Slide No. 5

6 Overview Introduction Design of a CFRP Hood CFD-Simulations Wind Channel Tests Summary # rh0140.ppt Slide No. 6

7 Design of a CFRP Hood Methodology CAD-Data of the Audi RS4 body Setup of the model (HyperMesh) Optimisation of the structure (Optistruct) Manufacturing of the CFRP hood Setup of a CFDmodel (SC/Tetra) Aerodynamic optimisation (SC/Tetra) Testing of an aluminium demonstrator Manufacturing of a tool # rh0140.ppt Slide No. 7

8 Design of a CFRP Hood Load Cases Analysis of the stiffness of the reference hood Target: design of a CFRP hood with equal performance concerning stiffness Longitudinal stiffness Lateral stiffness Torsion stiffness 481 N 481 N 100 N # rh0140.ppt Slide No. 8

9 Design of a CFRP Hood Optimisation of the CFRP Hood Definition of the design space (Catia) FE-modeling (HyperWorks) Constructive design Optimisation (Optistruct) # rh0140.ppt Slide No. 9

Design of a CFRP Hood First Results Outer sheet 1 x 0 2 x 45 1 x 0 Carbon layer construction Reinforcement structure 1 x 0 2 x 45 1 x 0 Mass [kg] Mass reduction potential 12 9.9 kg 10 8-60 % 6 4.

10 Design of a CFRP Hood First Results Outer sheet 1 x 0 2 x 45 1 x 0 Carbon layer construction Reinforcement structure 1 x 0 2 x 45 1 x 0 Mass [kg] Mass reduction potential kg % kg Aluminium hood CFRP hood Additional reinforcement 1 x 45 Reinforcement hinge 1 x 0 2 x 45 1 x 0 CRFP hood is 5,9 kg (65,5 %) lighter than aluminium hood # rh0140.ppt Slide No. 10

11 Overview Introduction Design of a CFRP Hood CFD-Simulations Wind Channel Tests Summary # rh0140.ppt Slide No. 11

CFD-Simulations Design of the Air-Outlet in the Hood Preparation of the FE shell model: Import of CATIA data of the body (half model) Creating different collectors for better model handling Filling

) Simplified design of the engine compartment Generating the mesh: Selection of appropriate shells (trias) Selection of appropriate shell sizes Requirements: - preferably exact mapping of the vehicle

12 CFD-Simulations Design of the Air-Outlet in the Hood Preparation of the FE shell model: Import of CATIA data of the body (half model) Creating different collectors for better model handling Filling of non-existant surface geometries (e.g. windows) Reduction of the model up to outer surfaces (deleting inner components) Simplification of critical parts (wheels, sharp edges etc.) Simplified design of the engine compartment Generating the mesh: Selection of appropriate shells (trias) Selection of appropriate shell sizes Requirements: - preferably exact mapping of the vehicle geometry - preferably exact mapping of the flow at relevant areas - preferably low total number of elements Equivalence of all element nodes Check and manual repair of critical elements Geometry of the Audi RS4 body Meshed Audi RS4 body # rh0140.ppt Slide No. 12

CFD-Simulations Pre-Processing for CFD-Simulation Creating a half

vehicle (with appropriate distance between vehicle and "walls",

vehicle, engine compartment and outer room enclose a volume)

multi-layerd boundary layer out of volume elements on the

13 CFD-Simulations Pre-Processing for CFD-Simulation Creating a half model with symmetry plane Generating of a closed room around the vehicle (with appropriate distance between vehicle and "walls", to enable a preferably uninfluenced simulated flow) Elimination of free edges (e.g. vehicle, engine compartment and outer room enclose a volume) Combination of single collectors to larger units Generating of a multi-layerd boundary layer out of volume elements on the around-circulated surfaces (vehicle, road) Mesh of the "air" with tetraeders (interpolating size of the volume elements Input of the important parameters in SC/Tetra # rh0140.ppt Slide No. 13

14 CFD-Simulations Design of the Air-Outake in the Hood Analysed Variants # rh0140.ppt Slide No. 14

cooling system Removal of the licence plate support improves

15 CFD-Simulations Design of the Air-Intake for the Cooling System Licence plate support obstructs the inflow of the cooling system Removal of the licence plate support improves temparatures of cooling-water in the race # rh0140.ppt Slide No. 15

16 Overview Introduction Design of a CFRP Hood CFD-Simulations Wind Channel Tests Summary # rh0140.ppt Slide No. 16

17 Wind Channel Tests Pratical Optimisation in a Wind Channel New hood M1 Reduction of the intake M3 50 mm New hood with 200 mm reduced intake M6 M4 100 mm New hood with 6 mm Gurney flap M2 M6 200 mm M5 150 mm Reduction of the air intake reduces the turbulence on the hood # rh0140.ppt Slide No. 17

Wind Channel Tests Comparison with CFD-Simulation Wind channel tests Flow at 55 kph c w -vlaue 0.340 0.336 0.332 0.328 Turbulence M6 Uplift coefficient 0.324 0.

18 Wind Channel Tests Comparison with CFD-Simulation Wind channel tests Flow at 55 kph c w -vlaue Turbulence M6 Uplift coefficient M1 M2 M3 M4 M5 M6 Measurement ca cav cah M1 M2 M3 M4 M5 M6 Measurement Local exhaust ventilation # rh0140.ppt Slide No. 18

19 Overview Introduction Design of a CFRP Hood CFD-Simulations Wind Channel Tests Summary # rh0140.ppt Slide No. 19

Summary Mass reduction of 60 % by substitution of aluminium by

in CFD-simulation and in the wind channel Air-oulet was

channel Perfusion of the engine compartment was improved, c w

20 Summary Mass reduction of 60 % by substitution of aluminium by CFRP in the hood at equal performance Air-intake was optimised in CFD-simulation and in the wind channel Air-oulet was optimised in CFD-simulation, on the race track and in the wind channel Perfusion of the engine compartment was improved, c w -value was reduced and the downforce increased # rh0140.ppt Slide No. 20

21 Thanks for your attention! # rh0140.ppt Slide No. 21

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