Computational Fluid Dynamics Analysis of airflow around a car model

using Solidworks Flow Simulation

Version 13.02.2015, 01:35
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Introduction
The SolidWorks Flow Simulation is the fluid flow analysis tool that is fully
embedded in SolidWorks. The flow analysis includes the following steps:
1) Create an assembly in SolidWorks;
2) Create a project in SolidWorks Flow Simulation. The project contains all
the simulation settings and computation results;
3) Run the analysis: Solidworks solves the equations describing the fluid
flow;
4) Viewing the Flow Simulation results which include:
Flow visualisation:
» Vectors, Contours, Isolines
» Cut Plots, Streamlines, Isosurfaces
Numerical outputs:
» XY Plots (can be exported to MS Excel)
» Goals (can be exported to MS Excel)
» Surface Parameters
» Reference Fluid Temperatures
1. Build an Assembly of a Car in a Wind tunnel
First, build a car and a wind tunnel of realistic dimensions as described in Step
1, 2, and 3.
Step 1. Build a car of a basic shape
The object should be recognisable as a car, but not necessarily possessing all the
small features, such as rear view mirrors, and not necessarily being well
streamlined. Choose realistic car dimensions. The bottom of tyres should be flat
to mate them with the floor of the wind tunnel.
Create a new ‘Part’. Set Y as the vertical axis and Z aligned with the direction
of the car motion. Choose the right plane and click the sketch button to draw the
car sketch.

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Use the ‘three arc point’ tool to draw wheels, then draw a horizontal line in the
half circle as the bottoms of the tyres.

Remove the rest arc of tyres bottom by using ‘trim to closet’ in ‘Trim entities’
tool and clicking the surplus arc at the bottom.

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Similarly, remove segments of the car bottom line above the wheels so that a
close contour is completed. Use ‘Extruded boss/base’ tool in features ribbon are
to make the car 3-dimensional: extrude the sketch in x direction and set the car
width.

Now the tyres must be cut. There are many ways to create wheels such as draw
a car body and add four wheels separately. Here, we draw a rectangular contour
like in the picture and use the ‘Extruded cut’ tool remove the surplus matter
“between wheels”.

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Finally, a body with four wheels is created as shown below.

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Step 2. Build a wind tunnel
Use the same way as above to create a new solid part document where build a
wind tunnel. Note that the wind tunnel should be large enough to reduce the
influence of walls on the flow around the car model as much as possible. For
example the wind tunnel dimensions can be 26m×9m×7m, and its wall
thickness can be, say, 500 mm.
There are many ways to build a wind tunnel. One simple way is to make a block
and hollow it by using the extruded cut command. First create a block
26m×9m×7m. And, insert a reference plane in the Features menu (‘Reference
Geometry’ tab) 0.5 m away from one end of the wind tunnel. Then, sketch a
smaller rectangle (8m×6m) on the reference plane and use the ‘Extruded Cut’
command (25 m) to remove the inside of the block. Please use the extrude cut
only for 25 m, so that and the windtunnel wall thickness is 0.5 m. Make sure
both ends of the wind tunnel are closed. Otherwise, you need to add lids on both
ends. Some steps are shown as below.
1) Using the ‘Corner rectangle command’ to draw the wind tunnel on
the front plane. Make sure the length of wind tunnel aligns with Z-axis.

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2) Dimensions of the rectangle are 7000 mm×9000m.

3) Extrude the rectangle by 26000mm (Extruded Boss/Base command).

The block is ready. Now, need to make it into an empty box.

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5) Insert a reference plane to sketch a rectangle as the end wall of the inner
surface of the wind tunnel.
The reference plane should be placed inside the body of the block 500
mm away from the end wall. If the plane is outside of the block, then tick
the flip and the reference plane will move inside the block.

6) Sketch the rectangle on the newly created reference plane.

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7) Use the ‘extruded Cut’ command to hollow the block (25000mm). The
wind tunnel is now ready as shown below.

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Step 1.3. Place the car inside the wind tunnel
1) Create a new Assembly file for the car in the wind tunnel.
Insert the ‘Car part’ and ‘Wind Tunnel part’ in, by ‘Insert Components’
command in ‘Insert Components’ tap of assembly ribbon.

2) In order to be able to see the car inside the wind tunnel, right click on the
‘Wind Tunnel’ part and choose ‘Component displayHidden Lines
Visible’ to make it transparent.

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3) Mate the side surface of the car model and the wall surface of the wind
tunnel: use the ‘Mate’ tool from the ‘Assembly’ toolbar. Select the
wind tunnel surface and car side surface. Mate by parallel and define
distance (say 4.2 m). Make sure the car is placed in the middle of the
wind tunnel.

4) Mate the bottom surface of one of the wheels of the car model and the
inner surface of the bottom of the wind tunnel by using Coincident
command. Other wheels will level with the floor automatically. To select
the inner, not outer surface of the wind tunnel. If not right click and
choose ‘select other’ option, then you can finally find the right surface.

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Mate the front surface of the car model and the inner surface of the end of the
wind tunnel by using Parallel command and defining distance (say 8.0 m).
Finally, the car is placed in the wind tunnel.

Note:
Position the car exactly in the middle between the walls (by using ‘Mating’
command again) and slightly closer to the inlet of the wind tunnel to enable
better resolution of the wake behind the car.
2. Aerodynamics Analysis of the Car using Solidworks Flow Simulation
Check before using SolidWorks Flow Simulation. If the flow simulation
toolbox is not installed by default, click Tools, Add-ins, and then click
SolidWorks Flow Simulation 2013 to load SolidWorks Flow Simulation.

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Now, perform the aerodynamic analysis of the car.
2.1 Create a Flow simulation Project
Step 1. Set up the Flow Simulation
1) Click Flow Simulation, and go to Wizard .
2) Configuration name for the project: select create new to create a
new configuration, name it in an illustrative way, for example,
‘Car_non_streamlined_20mps’, and click Next.

3) Unit System: Choose SI (m-kg-s) in the Unit system column, then

click Next.

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4) Analysis Type and Physical Features: Leave all the setting as it is,
do not tick any physical features. Then click Next.

5) Default Fluid: under Gases, select Air and then click Add. Flow type
will be Laminar and Turbulent with no regard to compressibility
and humidity. Then click Next.

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6) Wall Conditons: Default thermal condition is the Adiabatic wall (no
heat exchange) and zero roughness. Click Next.

7) Environmental Conditions: First leave Pressure 101325 Pa

(standard pressure), Temperature 293.2 K (room temperature) and
some Turbulence intensity (say, 2%). As mentioned in a briefing
lecture, the “Turbulence intensity” is a somewhat arbitrary parameter
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 which in reality varies across the flow domain. Being unable
predicting it, one usually choses the value providing results most
similar to experimental.
8) Set Velocity in Z direction 20 m/s, and Turbulence length 0.05 m.
Again, a somewhat arbitrary parameter characterising turbulent eddy
size. Click Next.
Note that in real world, the car would be moving through the stationary air. In a
wind tunnel, the car is stationary and air is moving. These set-ups are identical
except for the air behaviour in the gap under the car.

9) Results and Geometry Resolution: Manually specify the minimum

gap size (say, 0.05m), and the minimum wall thickness (say,
0.05m). Click Finish.
The “result resolution” should be set to yield acceptably accurate results within
a reasonable amount time. Ideally, compare results obtained at different result
resolutions to find the acceptable minimum.

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Step 2. Set up Boundary Conditions and Simulation Goals
Flow simulation analysis tree
A tab for the Flow Simulation analysis tree is added
to the Feature Manager area. Click on the Flow
Simulation analysis tree tab . Expand the Input
Data listing.

Set up boundary conditions

In the Flow simulation drop-out menu select the Boundary conditions. It
includes two setting ups: inlet and outlet.

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 1) Set up the Inlet boundary conditions
Select the inner face of wind-tunnel’s front end (right clickselect other
option) and set the inlet velocity flow, 20 m/s (72 km/h, 45 mph). Then a range
of arrows appear, if not, left click and select ‘Show’. Now, the arrows will turn
up.

Type: inlet-
Inlet Velocity

2) Set up the Outlet boundary conditions

On the outlet, set the environment pressure. Select the inner face (inlet and
outlet), right clickselect other and then choose from the planes in the list.

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Setting up the simulation Goals
Insert global goals
Now set up simulation goals. These are used as a criteria
of when to stop simulation. The software assumes that
when the values called goals stop changing, the flow
field is calculated with the sufficient precision and the
calculation can be stopped. A number of parameters can
be used, for example the “Turbulent Energy” goal.

Right click Goals in the Flow Simulation analysis tree

and select the Insert Global Goals from the shortcut
menu. Select the Turbulent Energy, or Forces, or some
other parameter which seems appropriate. If the
simulation runs for long enough, the answer does not
depend on which exactly parameter was used for
monitoring of the progress.

Insert Surface goals

Now, the task is to find forces acting on the car: drag (the force in streamwise
direction), lift (vertical force), and the side force.
Surface goal is a physical parameter calculated on a user-specified face (or
faces) of the model.

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Select the whole car without flat bottoms of the wheels mated to the wind tunnel
as they are not in contact with the flow and insert X, Y, and Z forces as surface
parameters. Then, separately, select a front panel of the car (for example, as
shown in the figure below) and set the force acting on it in streamwise direction
as a Surface Goal.

Step 3. Running the Analysis

All is set up now, it is time to run the simulation.
Run the analysis
Right-click the project name and click Run.
Alternatively, click Flow Simulation, Solve,
Run, or click Run Solver on the Flow
Simulation toolbar.

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Solver information
The Solution Monitor window appears after few seconds or so. On the right of
the window, the log steps taken in the solution process is displayed. On the left
is the information window with mesh information and any warnings.

Usually, the simulation takes less than half an hour. You may spend this time
performing back-of-the-envelope estimates required in the task (6) in the “lab
report” section.

Goal Plot

When you click Goal Plot , the Add/Remove Goals dialog appears. Select
the goals whose plots you want to view and click OK.

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For each goal selected in the Add/Remove Goals dialog box, the Goal Plot
shows the goal convergence diagram. The goal plot is an illustration how the
iterative solver works and does not represent any physical values.

Goal Table
Goal Table shows the list of all specified goals and contains the same
information as the upper portion of the Goal Plot window.

Save the file

After investing time in running the analysis it is prudent to save your work.

2.2 Viewing the Results

Once the calculation is finished, you can view the saved calculation results
through numerous Flow Simulation options in a customized manner directly
within the graphics area. The results options are:
» Cut Plots (section view of parameter distribution)
» Surface Plots (parameter distribution on a selected surface)
» Isosurfaces

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» Flow Trajectories (streamlines and particle trajectories)
» Goal Plot (behaviour of the specified goals during the calculation)
» XY Plots (parameter change along a curve, sketch)
» Surface Parameters (getting parameters at specified surfaces)
» Point Parameters (getting parameters at specified points)
» Report (project report output into Microsoft Word)
» Animation of results
We will view the flow trajectories and surface plots the next.

Step1. Load the results.

Right-click Results in the Flow Simulation analysis tree and select Load. If
Unload appears in the list, the results have already been loaded.

The Load Results window opens. Select 3.fld (or whichever file appropriate)
and click Open to load the results file.

Step 2. Mesh

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Insert the Mesh plot: Right click Mesh3D view (below the results). Note
that it is only possible to perform when the simulation is finished as the mesh
construction is a part of the simulation. For the Fluid cells, set its value All.
Then click Apply and OK.

Zoom in the mesh plot and note that the mesh is finer around the model corners
and curve surfaces.
Note: If you cannot see the mesh, right-click the wind tunnel and go to the
Component DisplayWireframe.

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Save the results by using screenshots which will be included to your report.

Step 3. Flow Trajectories

Plotting flow trajectories is a way to qualitatively understand the computed flow
structure. They are analogous to the streamers of smoke in a wind tunnel.

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To illustrate the flow structure around the car,
insert the flow trajectories adjacent to different
panels. Present a set of plots sufficient to
recognize main features of the flow. Check
whether the flow separates from the back of
the car. It does separate from the back of a car
in real life.
Insert a flow trajectory
Right-click Flow Trajectories in the Flow
Simulation analysis tree, and select Insert.
Select one or several faces of the car body, for
example, the front panel and the windscreen as
shown below. The streamlines located close to
the selected
surfaces will be
plotted.
Set the Number of Points to, for example, 50. For
Draw trajectories as, select Line with Arrow and
set value, for example, 0.01m. Leave the other
settings at their default values. Select the car front
panels for the panel of Starting Point. Then click
tick.

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Adjust the colour scale to visualise pressure.
The colour if streamlines represents pressure. Click on the top value of the
legend and enter the value relevant for your simulation (in this example it is
101575 Pa). Repeat this process for the bottom value (here, 100930 Pa).

 
Select the legend, then right clickEdit, set the top and bottom value in the
blanket.

Note: The main reason not to use the default values but to enter specific ones is
because when the design is changed, the minimum and maximum pressure
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values will be different. That means red would represent one pressure on one
plot and a different pressure on another plot. Using the same minimum and
maximum settings for each analysis allows for meaningful comparisons
between different iterations of the design.

Experiments with streamlines

There are two ways to alter the streamline plots:
» Edit the definition of the existing plot
» Insert a new plot
When multiple sets of flow trajectories are present at a plot, they can be
displayed selectively.
To hide the flow trajectory, right-click Flow Trajectories 1 and select Hide.
To insert a new flow trajectory, right-click Flow Trajectories, and select
Insert.
Select left side panel of the car. Set the Number of Points. For Draw
trajectories as, select Line, set value 1. Click OK.

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Examples of streamline plots are shown below.

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The plot with lines of the flow separation marked. In this case, the flow leaves
the car surface at almost every sharp corner. The picture will be more
complicated for rounded shapes.

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4) Cut Plots
To insert a cut plot is just like the way of inserting a new flow trajectory. Right
side plane cut plot of the car and its results.

Select appropriate colour scheme, so that the pressure features will be visible.
Think why the pressure is higher in some areas and lower in the others.
Compare pressure with its free stream value.
If too few or none contours are seen on the plot, try to narrow the limits of the
pressure scale. For example, if the whole plane looking like above figure almost
all is light green, change the scale limits to 101480 and 101150.

Then, insert a cut plot for the back of car and the legend limits is changed into
101329 Pa and 101279 Pa.

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3. Lab report
1) Present a screenshot of the computational mesh.
2) Illustrate the flow structure around the car by presenting few to several
streamline plots. Among others, the flow structure in the wake behind the car
must be visualised.
3) Present a set of pressure cut plots. Explain why in some area the pressure is
higher and in some lower than the free stream pressure.
4) Identify lines of the flow separation i.e. the lines where the flow leaves the
car surface. Mark the lines by hand (using Paint or any other image editing
software) at the car surface;
5) Present aerodynamic forces acting on the model
The preceding examples of flow trajectories and cut plots were excellent tools
for visualizing how the air flows and pressure around the car. However, they are
more qualitative than quantitative. Let’s move on to a more quantitative
interpretation of results.
In the analysis tree, expand the Results listing and right clickGoal Plots.
Select Insert from the shortcut menu. Click All. Click OK.

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When click Export to Excel, the MS Excel is launched and a spreadsheet opens.
The first three columns show the name of the goal, the units and the computed
value.

6) Select a panel, for example, the front one. Cite the total force acting on the
selected panel (a surface goal) and compare it with the order-of-magnitude
1
estimate 𝐹 ≈ 𝐴 ∙ 𝜌𝑉 2 , where 𝐴 is the area of the panel, 𝜌 is the air density
2
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(1.2kg/m ), and V is the free stream flow speed. Dose the calculation make
sense?
Note: To calculate the area of select surface, you can use the dimension you
sketch at very beginning. Or you can click the Evaluate tab and select the
Measure, then the area of selected face will show.
7) Cite the drag force acting on the model and find the power required to
overcome the drag (both in KW and in Horse Powers);
8) Cite the lift force acting on the model. Compare it with the car weight. Is the
anti-wing (also known as spoiler) useful in this case?
9) Improve the car aerodynamics
To minimize the drag, a car should have a shape which keeps the flow attached.
In other words, the flow separation should be avoided. Using lines, arcs and
splines to smooth the edges to prevent flow detachment, make the faces oblique
to the flow etcetera.
When optimising the shape, a restriction is imposed:
DO NOT change the car frontal area, i.e. the area of the car silhouette as view
from the front. For example, rounding corners like in Fig. 3.1, has changed the
area. The modification shown in Fig 3.2 keeps frontal area constant. Perform

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calculation with the streamlined model and discuss the results. Watch carefully
the flow structure in the wake behind the car: only for a very streamlined shape
the flow will remain attached to the car. You may need to introduce an artificial
kink at the rear of the model to ‘tell’ the software that the flow must detach
from the car body.

Fig. 3.1

Fig. 3.2
10) Plot and compare the flow structure around the basic and the streamlined
model and comment on the differences. Indicate lines of the flow separation
for the streamlined model.
11) Cite and compare lift and drag force acting on the basic and streamlined
cars. Calculate the drag coefficients 𝐶𝐷 of the basic and streamlined cars from
1
the formula 𝐹𝐷 = 𝐹𝑟𝑜𝑛𝑡𝑎𝑙𝐴𝑟𝑒𝑎 ∙ 𝐶𝐷 ∙ 𝜌𝐴2 Here the area of the car frontal
2
silhouette is used. Note that for a reasonably shaped car 0.2>CD>1. If the
coefficient obtained is not in this specific range, either find the error or explain
the computation outcome.
12) Calculate and compare the engine power required to overcome the drag for
basic and streamlined cars. Calculate the fuel consumption in miles per gallon

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if the energy loss occurs only due to the aerodynamic drag. Assume the engine
efficiency 25% and the petrol calorific value of 45 MJ/kg.

Avoid the over-precision in answers. At the level of aerodynamic modelling

the SolidWorks provides, 3 significant figures are more than enough when
citing calculated values.

The Lab report should contain streamline plots, cut plots, and address the
tasks from 1 to 12 and should not exceed 6 pages.

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