1. Race Car Aerodynamics GDP
MSc Race Car Aerodynamics
Z. Chen, B. Dufour, C. Elliott, F. Harrold, C. Jacques, N. McDowell and R. van der Meer
2. Introduction
Good aerodynamic design reduces lap time
Improve the aerodynamics of a hill-climb car
model
CFD enables analysis of different concepts at
low cost
2
4. Aim & Objectives
The aim of this project is “to accurately determine and improve the
aerodynamic performance of a hill climb car model using CFD”
First semester objectives were:
– Determining the regulations and general performance levels of hill
climb race cars.
– Gaining a clear understanding of the devices used to add aerodynamic
performance to a race car.
– Setting up a valid CFD simulation of a baseline race car model to
accurately determine its aerodynamic performance.
4
5. Aim & Objectives
Second semester objectives were:
– Making alterations to the model to improve aerodynamic
performance.
– Quantifying the impact of these alterations using CFD.
– Optimising the alterations and ensuring they result in a holistic
design.
5
7. CAD Corrections
Baseline CAD was unsuitable.
Modifications made:
– Realignment of Rear Wing
– Realignment of Sidepods
– The addition of relationships between respective parts
– CFD Preparation
– Changing of the axis system to ensure usability later on
7
8. Boundary Conditions
Boundary Conditions
Car Surface No Slip Wall
Inlet Velocity Inlet
Outlet Pressure Outlet
Engine Intake Pressure Outlet
Sidepod Intake Pressure Outlet
Ground Moving Wall
Symmetry Plane Symmetry
Top and Side Walls No Slip Wall
8
10. Domain
Cross section:
Based on the RJ
Mitchell wind tunnel
Length:
Roughly 3 car lengths upstream and 5 car lengths downstream
10
11. Solver
Solver Parameter Value
Space Three Dimensional
Time Steady
Material Gas
Flow Segregated
Equation of State Constant Density
Viscous Regime Turbulent
Reynolds Averaged Turbulence K-Epsilon
Relaxation Scheme Gauss Seidel
Turbulent Specification Intensity and Viscosity Ratio
Turbulent Viscosity Ratio 10
11
12. Mesh Settings
Mesh Parameter Value
Base Size 1.0m
Maximum Cell Size 0.25m
Maximum Core/Prism Layer Transition Ratio 2
Prism Layers 8
Prism Layer Stretching 1.05
Prism Layer Thickness 0.01m
Surface Curvature 180 points per circle
Surface Growth Rate 1.3
Minimum Surface Size 0.001m
Maximum Surface Size 0.5m
Template Gowth Rate Very Slow
Wrapper Feature Angle 30 deg
Wrapper Scale Factor 25% 12
13. Domain and Mesh Independence
Domain Length (m) CL CD Efficiency
17 -2.025 0.805 2.515
18 -1.989 0.837 2.376
-2.10
-2.05
-2.00
-1.95
-1.90
-1.85
-1.80
0.0E+00 2.0E+06 4.0E+06 6.0E+06 8.0E+06 1.0E+07 1.2E+07 1.4E+07 1.6E+07
CL
Number of Cells
Baseline Mesh Independency Study
• Mesh independence tested
by varying base size
between 0.7-5m
• Mesh found to be stable for
most runs
• Domain independence showed
small changes through
lengthening
• Minimal changes
13
14. Y-Plus
• Below 30 in regions of stagnation and separation
• Average 50
14
16. Objective
Increase lift coefficient value above 4
Keep drag coefficient value below 1.2
Increase efficiency
Drivable aerodynamic balance (39% to
44% front)
16
17. Hardpoints
The following were considered unchangeable:
Mass flow into the sidepod and engine air intake (within 5% of baseline)
Shape of the wheels
Wheelbase of the vehicle
Shape and position of driver
17
18. Member Allocation
Person Area of Car Group Tasks
Barret Sidepod Communication and Organization
Chen Engine Cover and
Nose Cone
CAD Assembly
Craig Front Wing CAD Assembly, Third Iteration Simulation, Report Proof Reading
Cyril Underbody Full Car Data Processing, First Iteration Simulation, Second Iteration
Simulation
Francis Rear Wing and
Exhaust
Baseline Simulation Setup and Runs, First Iteration CAD Assembly, Interim
Presentation Assembly, Third Iteration Simulation, Report Proof Reading
Nicky Front Wing CAD Corrections, Baseline Simulation Setup and Runs, Third Iteration
Simulations
Robbin Underbody Assembly of Report, Second Iteration Simulation, Third Iteration Simulation,
Project Planning and Supervision
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20. Lift, Drag, Efficiency & Balance
Car (Unit) CL CD Efficiency % Front Balance
Baseline -2.02 0.805 2.52 24.4
Frontal area: 0.08022687m²
Downforce and drag are both low
Balance is too far rearward
20
21. Components breakdown
35.74%
55.58%
10.48%
-9.81%
-9.36%
17.37%
-20.00% -10.00% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00%
Components CL breakdown
Underbody
Sidepods
Wheels
Body/Nose
Rear Wing
Front Wing
In terms of downforce:
Rear wing is the part producing most of
the downforce
Unbalance between front and rear wing
Underbody is only producing 17%
Sidepods is high, nearly 10%
In terms of drag:
Wheels are producing most of the drag
The other source is the rear wing
Rest is about 7-10%
7.43%
22.69%
7.14%
44.66%
9.60%
8.49%
Front wing
Rear wing
Sidepods
Wheels
Body/Nose
Underbody
0.00% 10.00% 20.00% 30.00% 40.00% 50.00%
Components CD breakdown
21
22. Pressure Coefficient
Top view
– High pressure visible on the rear wing pressure
side
– Low pressure on the side pod inlet
Side view
– Low pressure on the outer side of both rear and
front tyres
Bottom view
– Pressure on the underbody is close to zero
– High pressure on the diffuser inlet
22
23. Pressure Coefficient
Front view
– High pressure region on the nose cone,
inner side of the front tyres and bottom of
the sidepod inlet
Rear view
– Separation developing on the diffuser
23
27. Front Wing – Width Study
This study was focused
primarily around efficiency of
the full car
Optimal reviewing the data
points lies between 80-
87.5% width 2.5
2.55
2.6
2.65
2.7
2.75
2.8
2.85
2.9
70% 75% 80% 85% 90% 95% 100%
Efficiency,L/D
Wing Width, % of Total width allowed
Wing Width Study, Efficiency
27
28. Front Wing Iteration 1
Endplate Refinement:
Addition of Footplate
Turning Vane for optimised
flow
Sweep angles tested to reduce
separation but channel
underfloor flow
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32. Underfloor
Diffuser shape changed to an aerofoil shape: S1223
Venturi channels included into the underfloor design and
tucked inwards.
Diffuser is extended from 159 to 423mm behind the rear
wheels and widened as closest as possible to the rear tyres.
Two different exit heights tested: 150mm and 170mm.
Flat plates installed on the side of the diffuser.
Inlet shape was also modified.
32
33. Underfloor
Significant increase in downforce
Moderate increase in drag
The 170mm exit height has proven to be the best
Less separation visible on the diffuser
Recirculation region removed from the inlet
33
-0.1
0.2
0.5
0.8
1.1
1.4
1.7
2
2.3
2.6
2.9
CL
CL Breakdown Comparison
Baseline car Design 2 : 150mm Design 2 : 170mm
-0.05
0.05
0.15
0.25
0.35
0.45
0.55
0.65
0.75
0.85
CD
CD Breakdown Comparison
Baseline car Design 2 : 150mm Design 2 : 170mm
34. Rear Wing
Changed all aerofoil profiles to Selig-1223.
Rotated first element to -5 degrees AoA.
Beam wing lowered by 60mm.
Beam wing and diffuser interaction led to
removal of beam wing.
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Baseline First Iteration
37. Lift, Drag, Balance & Efficiency
Model CL CD
Aerodynamic
Efficiency
% Front
Balance
Baseline -2.02 0.805 2.52 24.4
First Iteration -3.07 0.925 3.31 31.2
52% increase in downforce production.
15% increase in drag production.
31% increase in efficiency.
7% increase in balance towards the front of the
car.
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38. Component Breakdown
-0.3
0
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3
Total Fwing Rwing Sidepod Wheels Body & Nose Underbody
CL
Component Lift Coefficient Breakdown
Baseline car First Iteration
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Total Fwing Rwing Sidepod Wheels Body & Nose UnderbodyCD
Component Drag Coefficient Breakdown
Baseline car First Iteration 38
45. Nose Cone
Made the nose higher to help
diffuser
Connected the nose and
splitter curve
Reduced the effect on the
trailing edge of the front wing
CFD results:
Runs Overall CL Overall CD Front Wing CL Rear Wing CL Diffuser CL Efficiency
Iteration 1 -2.98 0.93 -1.07 -1.14 -1.30 3.20
Iteration 2 -3.15 0.95 -1.16 -1.14 -1.39 3.33
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46. Underfloor
Modifications were brought to an “idealised car”
Run Diffuser CL Diffuser CD Overall CL Overall CD Efficiency
First Iteration Car -1.31 0.145 -3.07 0.925 3.31
Idealised Car -1.41 0.164 -2.68 0.937 2.86
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47. Underfloor
Different area ratios were tested
Lower pressure appearing on the diffuser
Throat Exit Ratio to
ground
clearance
Diffuser
CL
Diffuser
CD
Overall
CL
Overall
CD
Efficiency
15 170 6.34 -1.41 0.164 -2.68 0.937 2.86
20 170 5.41 -1.55 0.164 -2.93 0.942 3.11
20 190 6.00 -1.74 0.176 -3.09 0.953 3.25
20 210 6.59 -1.85 0.189 -3.17 0.965 3.28
20 230 7.18 -1.90 0.198 -3.26 0.994 3.28
20 250 7.76 -1.87 0.204 -3.07 0.993 3.10
25 265 7.15 -1.90 0.209 -3.18 1.02 3.13
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49. Underfloor
Area ratio optimized from 7.18 to 7.47
New side pod included in the design
Flat plates added behind the rear wheels
Runs Diffuser
CL
Diffuser
CD
Overall
CL
Overall
CD
Efficiency
T20 E230 with upward skirts -1.95 0.200 -3.20 0.975 3.28
T20 E220 with upward skirts -1.92 0.197 -3.17 0.963 3.29
T20 E240 with upward skirts -1.96 0.205 -3.22 0.983 3.28
T20 E240 with upward skirts
and iteration 2 side pod
-1.94 0.204 -3.40 1.01 3.36
T20 E240 with upward skirts,
iteration 2 side pod and rear flat
plates
-2.00 0.208 -3.46 1.01 3.42
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50. Rear Wing
Slot gap and Overlap Optimisation
Remodelled mounts
Redesigned endplates
Rear wing positioning optimisation
First iteration Second Iteration
50
Model CL CD Efficiency
Revised Iteration 1 -2.871 0.970 2.960
Iteration 1 with New
RW
-3.092 0.935 3.307
53. Lift, Drag, Balance & Efficiency
Model CL CD
Aerodynamic
Efficiency
% Front Balance
Baseline -2.02 0.805 2.52 24.4
First Iteration -3.07 0.925 3.31 31.2
Second Iteration -3.47 1.010 3.42 34.3
• 11.5% increase in downforce production
• 8.4% increase in drag production
• 3.2% increase in efficiency
• 3.1% increase in balance towards the front of the car
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54. Component Breakdown
54
-0.3
0
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3
3.3
Full car Front Wing Rear Wing Sidepods Wheels Body/Nose Underbody
CL
Component Lift Coefficient Breakdown
Iteration 1 Iteration 2
-0.05
0.05
0.15
0.25
0.35
0.45
0.55
0.65
0.75
0.85
0.95
1.05
Full car Front Wing Rear Wing Sidepods Wheels Body/Nose Underbody
CD
Component Drag Coefficient Breakdown
Iteration 1 Iteration 2
57. Front Wing
Movement of wheels outboard of the car
Introduction of Strakes
Re-introduction of the middle of the wing
Carried Forward:
Re-introduction of the middle of the wing
57
58. Front Wing
Vortex Channel Configuration CL CD
Wide Main, Original Cascade -3.47603 1.010946
Original Main, Original Cascade -3.57881 1.011578
Original Main, Narrow Cascade -3.60611 1.011733
Capturing Vortices:
Optimum width for mainplane
elements
Optimum width for cascade
elements
Vortex Generator design and test
58
60. Third Iteration-Nose Cone
Improved the front wing performance by
pressing the front nose down
Improved the flow around the trailing edge of
the front wing by making the middle nose higher
Moved the balance towards
Was not carried forward
CFD results:
Runs Overall CL Overall CD Efficiency Front Wing CL
Diffuser
CL
% Front
Balance
Iteration 2 -3.461 1.012 3.419 -0.960 -1.940 34.3
Iteration 3 -3.434 1.003 3.424 -1.010 -1.824 39.4 60
61. Underfloor
Vortex generators and fins
Zoom in on both devices
Runs Diffuser CL Diffuser CD Overall CL Overall CD Efficiency
Second Iteration Car -2.00 0.208 -3.46 1.01 3.42
Vortex Generators -2.02 0.208 -3.48 1.01 3.45
Fins -2.02 0.209 -3.48 1.01 3.45
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62. Underfloor
Barge boards
Turning Vane
Runs
Diffuser
CL
Diffuser
CD
Overall
CL
Overall
CD
Efficiency
Second Iteration
Car
-2.00 0.208 -3.46 1.01 3.42
Barge Boards -1.98 0.217 -3.45 1.01 3.42
Single Turning
Vane
-2.07 0.214 -3.52 1.01 3.50
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64. Underfloor
Gurney flap
Wing element
Runs
Diffuser
CL
Diffuser
CD
Overall
CL
Overall
CD
Efficiency
Second Iteration Car -2.00 0.208 -3.46 1.01 3.42
Gurney Flap added -2.30 0.303 -3.68 1.07 3.45
Wing element added -2.41 0.368 -3.76 1.12 3.35
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65. Underfloor
Testing the Gurney Flap on the Final car at
different speed
30m/s
Runs Velocity m/s Diffuser CL Diffuser CD Overall CL Overall CD Efficiency
Third Iteration Car 30 -2.84 0.422 -4.48 1.14 3.93
Gurney Flap added 30 -3.86 0.899 -5.43 1.52 3.57
Third Iteration Car 150 -2.62 0.247 -4.60 1.02 4.52
Gurney Flap added 150 -2.90 0.348 -4.80 1.08 4.45
150m/s
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66. Exhaust Reimplementation
Rear Wing improvements were limited through
diffuser developments
Exhaust reimplementation was deemed to
add a larger performance gain
Exhaust added to engine cover
Exit speed calculated at 109.62m/s
Tested over a range of exit angles
Second Iteration Third Iteration
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CL CD
Exhaust Setting Full Car Rear Wing Diffuser Full Car Rear wing Diffuser
No Exhaust -3.832 -1.022 -2.389 0.989 0.240 0.260
Optimised -4.597 -1.112 -3.093 1.133 0.244 0.461
69. Lift, Drag, Balance and Efficiency
Model CL CD
Aerodynamic
Efficiency % Front Balance
Baseline -2.02 0.805 2.52 24.4
First Iteration -3.07 0.925 3.31 31.2
Second Iteration -3.47 1.010 3.42 34.3
Third Iteration -4.48 1.142 3.93 32.1
22.5% increase in downforce production
3.7% increase in drag production
13.0% increase in efficiency
2.2% reduction in front balance
69
70. Component Breakdown
70
-0.5
-0.2
0.1
0.4
0.7
1.0
1.3
1.6
1.9
2.2
2.5
2.8
3.1
3.4
3.7
4.0
4.3
4.6
Full car Front Wing Rear Wing Sidepods Wheels Body/Nose Underbody
CL
Coefficient of Lift Breakdown Comparison
Iteration 3 Iteration 2
-0.05
0.05
0.15
0.25
0.35
0.45
0.55
0.65
0.75
0.85
0.95
1.05
1.15
Full car Front Wing Rear Wing Sidepods Wheels Body/Nose Underbody
CD
Coefficient of Drag Breakdown Comparison
Iteration 3 Iteration 2
71. Component Breakdown
71
-0.5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
Full car Front Wing Rear Wing Sidepods Wheels Body/Nose Underbody
CL
Coefficient of Lift Breakdown Comparison
Iteration 3 Iteration 3: 150m/s
-0.05
0.05
0.15
0.25
0.35
0.45
0.55
0.65
0.75
0.85
0.95
1.05
1.15
Full car Front Wing Rear Wing Sidepods Wheels Body/Nose Underbody
CD
Coefficient of Drag Breakdown Comparison
Iteration 3 Iteration 3: 150m/s
74. Reynolds Scaling Effects
Velocity
(m/s)
CL CD Balance
% Front
Balance
% Rear
Efficiency
30 -4.4823 1.1416 0.3206 0.6793 -3.9261
60 -4.4228 1.0458 0.4365 0.5634 -4.2290
90 -4.4683 1.0256 0.4543 0.5456 -4.3568
120 -4.4710 1.0141 0.4628 0.5371 -4.4088
150 -4.6042 1.0185 0.4629 0.5370 -4.5203
Significant rearward balance at 30 m/s
≈ 23 mph full-car
Balance shifts forward as speed
increases
• Inertial forces dominate so reduced
separation
• Exhaust effect diminishes
Balance is 46% forward at 150m/s ≈
117 mph full-car
Efficiency increases at higher Reynolds
number
74
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0 20 40 60 80 100 120 140 160
%FrontBalance
Velocity (m/s)
Velocity against Front Balance
75. CFD Accuracy
Baseline car model
• Extensive verification
• Validation against force coefficients
• No comparison of flow field with experiment
Design alterations
• Carried over settings of baseline car
• Potential inaccuracy for radical geometry changes
• Ideally verify and validate further
75
76. Design Feasibility
There are some feasibility concerns as this is a purely aerodynamic investigation:
The rear wing mounts and the underbody are sticking out far rearward
The wing-shaped diffuser results in high engine positioning
The lack of suspension results in no attachment of the wheels to the car chassis
The limited space for the driver in the final nose design
76
77. Further Design Optimisations
Front Wing:
• Angles of attack
• Aerofoil shape
• Further analysis into inwash wings
• Bargeboard Endplates
77
Sidepod
• Optimize airflow from wheel cover to rear wing
• Vortex generators
78. Further Design Optimisations
Rear wing
• Teamwork with engine cover and diffuser
• Beam wing
• Channelling of the turbulent air emanating from the wheels
• Addition of cut-outs to the endplate
78
Diffuser
• Gurney
• Bargeboard ahead the diffuser
• An automated optimisation on the top surface
79. Conclusion
Baseline model simulated in CFD
• Extensive verification
• Validation against force coefficients
Design improvements made
• 3 design iterations were performed
• Coefficient of Lift value increased to 4.48
• Coefficient of Drag value kept relatively low at 1.14
Further work to be done
• Verify and validate CFD of final design
• Further optimise design and address feasibility concerns
79