Aerodynamics and CFD at Volvo Car Corporation

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1 Aerodynamics and CFD at Volvo Car Corporation KTH March 2011 Johan Ljungberg Volvo Car Corporation Page 1 Overview Background Influence of Aerodynamics - Why is aerodynamics important Development Facilities - Test Techniques - Moving Ground Page 2

2 Influence of Aerodynamics Drag (fuel consumption, top speed, acceleration) High-speed stability (lift) Cross-wind stability (side force and yawing moment) Passenger comfort (cabriolets) Cooling Performance Dirt deposition (visibility) Aero acoustics (limiting the strength of sources) Body deformation (Door frames etc) Page 3 Sources of drag on a modern car 45% 30% 25% Page 4

3 Aerodynamics part of total fuel consumption EU Combined cycle NEDC (Note! Average speed 33km/h) Electrical systems 16% Transmission losses 8% Drag 26% Lost kinematic energy during braking 29% Rolling resistance 21% Page 5 Aerodynamics part of total fuel consumption Constant speed 90km/h Electrical systems 8% Transmission losses 9% Rolling resistance 30% Drag 53% Page 6

4 Aerodynamics On the C30 DRIVe Page 7 C30 DRIVe: Aerodynamic parts Cooling air intake Front undershield Front wheel deflectors Page 8

5 C30 DRIVe: Aerodynamic parts Roof wing Cover plate Diffusor panel Floor panels Rear bumper Page 9 C30 DRIVe: Cd reduction -0,007-0,008 Issue date: , Security Class: Public Page 10

6 C30 DRIVe: Cd reduction (-0,002) (-0,002) -0,012 (-0,003) -0,008 (-0,002) Page 11 C30 DRIVe: Aerodynamic parts Special wheels (Libra) delta Cd (compared to steel rims) -0,005 (rotating) Lowered chassis delta Cd -0,005 Page 12

7 Aerodynamic drag reduced more than 10% compared to standard car Fuel consumption reduced by: 0,12 l/100km or 3g CO 2 /km (EU Combined) - (this corresponds to an equivalent weight reduction of approx. 80kg) 0,3 constant 90km/h Page 13 Challenges facing Aerodynamicists Styling Manufacturing Parts Assembly Packaging Visbility Other attributes (eg Thermo, dirt, handling ) Carry-over content Cost!!! Page 14

8 Aerodynamics through the ages Year Cd PV ,50 Amazon ,48 Cd v Year P ,48 P1800ES , , , , , , , , ,34 S ,31 V ,33 XC ,40 V ,35 S40N , ,39 480ES ,38 S ,34 V ,36 0,60 0,55 0,50 0,45 0,40 0,35 0,30 0, Page 15 Aerodynamics through the ages Year Cd PV ,50 Amazon ,48 CdxA v Year P ,48 P1800ES , , , ,42 1,20 1, , , , , ,34 S ,31 V ,33 1,00 0,90 0,80 XC ,40 V ,35 S40N , ,39 480ES ,38 S ,34 V ,36 0,70 0, Page 16

9 Aerodynamics through the ages Year Cd PV ,50 Amazon ,48 Frontal Area v Year P ,48 P1800ES , , , , , , , , ,34 S ,31 V ,33 XC ,40 V ,35 S40N , ,39 480ES ,38 S ,34 V ,36 2,90 2,70 2,50 2,30 2,10 1,90 1,70 1, Page 17 Development process Concept study Generic shape studies Evaluate styling proposals Define underfloor concepts Analysis and research of previous models and competitors Simple scale model tests (parameter studies) Semi-detailed CFD (parmeter studies) Create guidlines to design and engineering Create aerodynamic hard points Page 18

10 Development process Prestudy Develop frozen design Develop underfloor solutions Analyse and suggest improvements to many designs (CFD and models) Give recommendations when choosing design Develop and improve chosen design using full-scale clay model and fully detailed CFD modelling Confirm and approve the chosen design s predicted characteristics Page 19 Development process Fine tuning of pre-production prototypes Confirm and approve all characteristics Follow up any late design changes Confirm production car Project Detail optimization Verification Page 20

11 36-48 months Concept study Generic shape studies Evaluate styling proposals Define underfloor concepts Prestudy Develop frozen design Develop underfloor solutions Project Detail optimization Verification Page 21 In-house testing in three wind tunnels, Gothenburg PVT MWT Climatic Test section 27m 2 (6.6mx4.1m, length 15.8m) Max speed 250 kph Temp. +20 to 60 C Chassi dyn. load 150 kw Sun sim. max 1200 W/m 2 Wind tunnel facilities at Volvo 1:5 scale of PVT Test section 1.1m 2 Max. speed 200 kph Test section/nozzle 11.2m 2 Max. speed 200 kph Temp range -40 to +50 C Chassi dyn. load 280 kw Sun sim. max 1200 W/m 2 Page 22

12 Conventional aerodynamic testing Balance measurements Effect of configuration changes on aero coefficients Investigate sensitivity to flow angle, vehicle attitude and wind speed Turn table Wheel Drive Units Supporting struts Measuring frame Centre belt Page 23 Why Moving Ground is Neccessary Provides correct relative movement between the car body and tunnel floor Provides correct relative movement between the car body and wheels Influences flow under and around car Page 24

13 How: Stationary Floor and Wheels Wind Page 25 How: Moving Ground and Rotating Wheels Wind Road/Floor Page 26

14 Optimisation affected Roof and boot Wheel Design Front-end and deflectors Underbody design Page 27 Methods to increase the knowledge gained from aerodynamic testing Flow visualization (smoke, surface paint, tufts) Page 28

15 Methods to increase the knowledge gained from aerodynamic testing Pressure Measurements Page 29 Methods to increase the knowledge gained from aerodynamic testing Wake measurements = 2 2 D ( P + ρu P U ) dydz ρ 2 Seven-hole probe rake Floor traverse Page 30

16 Wake analysis Wake measurements 100 mm downstream of a notchback Total pressure Microdrag Identify regions that can be improved Page 31 Thank you for your attention! Page 32

Aerodynamics and CFD at Volvo Car Corporation

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