Aerodynamics and CFD at Volvo Car Corporation

Johan Ljungberg jljungb3@volvocars.com

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 1

Graduated from KTH 2005 Scania AB 2005-2006 Volvo Cars 2006-

Volvo graduate program

www.volvocars.com/intl/top/about/corporate/career/pages/graduate_program.aspx

Present at the CFD group: 16 employees

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 2

Outline
Introduction CFD process Hardware and Software Aerodynamics CFD Strengths of using CFD

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 3

What is CFD
The analysis of fluid flow, heat transfer, and other related phenomena with the aid of advanced numerical techniques, softwares and computers.

Why CFD
UNDERSTANDING complete picture of the flow field at any time COMPLEMENTS physical testing Meets the need for REDUCED LEAD TIME

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 4

History of the CFD Group

1990: 1991: Basically 2D computations 1:st computation of 3D external flow calculation 100000 cells lead time 3 to 4 months lead time of 6 weeks possibility of using CFD in the early stages of car development focus becomes model complexity lead time 8 weeks lead time for a detailed floor calculation is 4 weeks 60 million cells (2 days for a configuration)

1993:

2000: 2010:

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 5

CAE Groups at VCC

Durability and NVH Computational Fluid Dynamics

Safety and crash

Powertrain, Powertrain, Thermodynamics analysis Thermodynamics analysis Combustion Systems Combustion Systems

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 6

THERMODYNAMICS

CLIMATE SYSTEMS

AEROACOUSTICS
KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 7

CONTAMINATION

Software
Preprocessing:
TCE ANSA Harpoon Tgrid (FLUENT) Pro-am (STAR-CD)

Solver: FLUENT Radtherm

Post processing: Ensight FLUENT (Cfd-post) MATLAB

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 8

CFD Process
TCE CAD-Extraction ProAM Wrap ANSA
3) Simplied

HARPOON FLUENT ENSIGHT

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 9

CFD Process
TCE CAD-Extraction ProAM Wrap ANSA HARPOON FLUENT ENSIGHT Wrapping of complex Geometries to get an air tight geometry

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 10

CFD Process
TCE CAD-Extraction ProAM Wrap ANSA HARPOON FLUENT ENSIGHT Pre-work for wrapping Clean Exterior

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 11

CFD Process
TCE CAD-Extraction ProAM Wrap ANSA HARPOON FLUENT ENSIGHT Octree based Volume mesher

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 12

CFD Process
TCE CAD-Extraction ProAM Wrap ANSA HARPOON FLUENT ENSIGHT

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 13

CFD Process
TCE CAD-Extraction ProAM Wrap ANSA HARPOON FLUENT ENSIGHT

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 14

Hardware

PC VISTA (64 bits), 64-96 GB, 2 Processors

Used for pre- and postprocessing

SERVER 520 CPU:s (extra access to crash CPUs in case of free slots)

Used for the Solver

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 15

Aerodynamics CFD
Closed front / semi detailed Open front / fully detailed

Closed front, i.e no cooling flow

Detailed engine compartment

Symmetry condition
KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 16

None symetric

Aerodynamics CFD
Exterior optimization: closed front

Late separation

Good separation

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 17

Aerodynamics CFD
Exterior optimization: closed front

Skin friction

Velocity plane 100mm downstream base

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 18

Iso surface total pressure

Aerodynamics CFD
Morphing

+30 mm Ref -15 mm -30 mm

Roof height study: S80

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 19

Aerodynamics CFD
Morphing

+30 mm Ref -15 mm -30 mm

Roof height study: S80

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 20

Aerodynamics CFD
Morphing

Ref -10 mm -20 mm -30 mm

Greenhouse study: S80

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 21

Aerodynamics CFD

Cooling flow needed to optimize underbody details as deflectors and underbody panels

Underbody optimization: open front

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 22

Aerodynamics CFD

Challanges with wheel house aerodynamics

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 23

Aerodynamics CFD
Force (N) Exterior Front Wheels Rear Wheels Front Suspension Rear Suspension Front Wheel Deflectors Cooling Package Drive line Floor TOTAL 153,9 23,6 16,4 7,1 8,7 8,1 97,3 64,2 -62,4 317,25 Cd*A 0,331 0,051 0,035 0,015 0,019 0,018 0,209 0,138 -0,134 0,682 Cd 0,143 0,022 0,015 0,007 0,008 0,008 0,090 0,060 -0,058 0,295 % 48,5 7,5 5,2 2,2 2,8 2,6 30,7 20,3 -19,7 100,0

CD vs x

Drag per part

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 24

Strengths of using CFD

It is cheaper and faster than wind tunnel tests at early stages of the car development It provides the complete picture of the flow field It allows the brake down of the model for easier interpretation of the forces It allows direct comparison of the flow and local forces between configurations It is an excellent support and complement to wind tunnel tests Powerful tool to be used in combination with optimization

KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 25

STCC & WTCC

Thank you!
KTH, Johan Ljungberg, jljungb3 2011-03-25Issue date: 2010-04-19, Security Class: Public Page 26