Computational Fluid Dynamics (CFD)

CFD is an advanced simulation technique to analyze and predict fluid flow, heat transfer, and related physical phenomena.

We have applied CFD for many applications across various industries such as automotive, Powersports, aftermarket, industrial machines, boats, RV, etc.

Some applications in automotive domain includes:

  • Enhancing vehicle aerodynamics
  • Reducing drag to improve fuel economy
  • Maximizing the range of electric vehicles

Computational Fluid Dynamics (CFD) Applications

Computational Fluid Dynamics (CFD) has various applications in automotive engineering. Some of the key areas where CFD is used include:

  • Aerodynamics: CFD is used to analyze the flow of air around vehicles, including cars, trucks, and racing vehicles. It helps in optimizing the vehicle shape to reduce drag, improve fuel efficiency, and enhance stability.
  • Thermal management: CFD is employed to study the cooling of engines, brakes, and other vehicle components. It helps in designing efficient cooling systems to prevent overheating and optimize thermal performance.
  • HVAC systems: CFD is used to design and optimize the heating, ventilation, and air conditioning systems in vehicles to ensure proper airflow and temperature control inside the cabin.
  • Underhood airflow: CFD helps in analyzing the airflow around the engine and other components under the hood to optimize cooling and reduce aerodynamic losses.
  • Exhaust system design: CFD is used to study the flow of exhaust gases and optimize the design of exhaust systems for improved performance and reduced emissions.
  • Fluid-Structure Interaction: Investigating the interaction between fluids and solid structures, such as fluid-induced vibrations or fluid-structure interaction in marine and aerospace applications.

CFD plays a crucial role in engineering design and analysis, enabling engineers to understand complex fluid dynamics phenomena, optimize designs, and reduce the need for costly physical prototypes through virtual testing and simulation.

CFD Model
Aerodynamic

Aerodynamics

To predict and improve the aerodynamic drag coefficient of the vehicle to reduce power consumption using Computational Fluid Dynamics (CFD) techniques by creating a virtual wind tunnel. Vehicle design was iterated working closely with design studios for following key performance criteria:

  • Drag Reduction: By minimizing aerodynamic drag, vehicles can achieve better fuel efficiency and performance. CFD allows engineers to identify areas of high drag and optimize the vehicle’s shape to reduce it.
  • Lift Reduction: Excessive lift can reduce vehicle stability, especially at high speeds. CFD helps engineers design vehicles with aerodynamic profiles that minimize lift.
  • Downforce Optimization: For high-performance vehicles like race cars, generating downforce is essential for improving traction and cornering stability. CFD can be used to optimize vehicle designs to increase downforce without significantly increasing drag.

Underhood Thermal Prediction

  • Vehicle underhood thermal performance prediction
  • Coolant circuit 3D CFD simulation to determine pressure drops, flow distribution and heat balance in the coolant system
  • Aerodynamic simulation to determine air flow distribution, velocities, recirculation zones of vehicle.
  • Conjugate heat transfer simulations followed by FE analysis to determine themo mechanical behavior of various underhood sub systems. (Example: Radiator Assembly, EGR Cooler system, Engine Assembly etc.)
Underhood Thermal Prediction
Comfort Assessment
HVAC System Design

Comfort Assessment

Vehicle occupant thermal comfort refers to the sensation of comfort experienced by passengers and drivers regarding the temperature and humidity levels within the vehicle cabin. Achieving optimal thermal comfort is essential for enhancing the overall well-being and satisfaction of vehicle occupants, especially during long journeys or in extreme weather conditions. Here are some key considerations for ensuring vehicle occupant thermal comfort:

  • HVAC System Design: Develop an effective HVAC system by accounting all thermal loads
  • Temperature Control and Air Distribution: Ensure uniform air distribution throughout the cabin by strategically placing air vents and ducts to minimize hot spots or cold drafts. Direct airflow towards occupants’ bodies and adjust airflow direction and velocity to enhance comfort levels.
  • Insulation and Thermal Management: Use high-quality insulation materials and weather sealing to minimize heat transfer between the interior and exterior of the vehicle. Optimize thermal management systems to regulate cabin temperature effectively and reduce energy consumption.
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