1. Engineering Fluid Dynamics - EFD in Champ Car Koen Beyers - Voxdale

2. Voxdale   Founded in 2005   Mechanical Design & Engineering   Digital Prototyping, Simulation: FEA, CFD, …   Domains : – – Yachting : Etap – – Space : Esa, QinetiQ, Nasa, MAV – – Industry : Agfa, Barco, Niko – – Racing : Champ Car   Champ Car & Conquest Racing

3. Champ Car   World’s longest running racing series (1909)   “American F1” – – Lower budgets: $10,000,000 - $15,000,000 – – Small teams: 50 - 100 people – – Custom chassis (Lola, Elan Panoz,...) – – Levelled: Less Technology, More Spectacle   1.8 billion TV viewers   US, Canada, Europe, Australia & Mexico   Andretti, Mansell, Villeneuve, Montoya

4. “The ING Renault F1 Team is pleased to announce a major $50 million technology investment in a brand-new Computational Fluid Dynamics (CFD) facility. Improved simulation in CFD is of direct benefit … “ Press Release, July 30, 2007 ING Renault F1 Team

6. Champ Car - Conquest Racing - CFD

8. Process  3D Scan  Reverse Engineering & CAD  Computational Fluid Dynamics EFD  Design & Engineering Project : – Concept, Design, Simulation & Engineering – Updates, new parts, set-ups – Tools : Pro/E, Pro/Mech, EFD.Pro, MSC Goal = Optimising Custom Chassis (Panoz)

9. 3D Car Scanning  No CAD Files available - Panoz Chassis  Optical Laser Scanning – Metris, 0.3mm accuracy at 6m – STL point cloud, 5 GB  Basis for Reverse Engineering

10. 3D Car Scanning

12.  After import of the raw scan data, the continuation of the process is 100% done in Pro/ENGINEER Wildfire III.  CAD – Design of Components, Assemblies, Tables, … – AAX, ISDX  FEA – Pro/ENGINEER Thermal & Structural (Mechanica)  CFD / EFD (setup, mesh, solve, post-process) – EFD.Pro (Flomerics – Nika)

16. CAD - Chassis System Design  Components & Assemblies – Monocoque & Body work (ISDX) – Variants & Add-ons Winglets, Gurneys, Chimneys, (Brake) ducts, … – Structural sub-assemblies (simplified) Gearbox-engine, Cooling system, … – Suspension Tire camber, Toe-in & out, Steering, Wheel base, Height  Pro/E Family Tables, Lay-outs & Skeletons – Car Setup, easy manipulation in AAX

17. CAD - Chassis System Design

26. Engineering Fluid Dynamics - EFD  The Pro/E EFD model is derived from the complex assembly – The complete assembly would have too many details that would only boost mesh & computation time. – Through ‘Publish Geom’ in Pro/E, a simplified car assembly can be built, with all parametric functionalities still in place.  All EFD.Pro actions are carried out in Pro/E, on the native Pro/E Geometry.

27. Full Pro/E Assembly

28. Derived Pro/E EFD.Pro Assembly

29. Engineering Fluid Dynamics - EFD  EFD Model setup in an extra tab in the Pro/E Model-tree. – Computational domain, Gasses & Fluids – Velocity, Pressure, Temperature, Dissipation, Gravity  Car settings – Surface roughness – Moving ground, rotating wheels – Parameters : Suspension, wings, components – Sidepods, exhaust, ducts, chimneys … – ‘Half Car’ model > Symmetry plane.

30. EFD – Setup

31. EFD – Champ Car Project - Goals  Improved Drag/Downforce Ratio – Updated components, Variants – Gurneys, Cut slots – = Optimising for Speed.  Tweaked reliability – Improved reliability >> Exhaust fires – Narrowed reliability >> ‘Overcooled sidepods’ – = Optimising for Margins.

33. EFD – Output

34. EFD – Surface Plots

36. EFD – Cut Plots

39. EFD – Flow Trajectories

46. EFD – Mesh Zooming  Starts from a previous analysis  Reduced Computational Domain  Inputs at boundaries from previous simulation  Advantages : – Maximum mesh available for smaller domain – ‘Complete car simulations’ not needed for local optimisation.

47. EFD – Mesh Zooming - Sidepod

52. If You Have An Image To Insert …

54. EFD – Mesh Zooming - Exhaust

61. EFD & Structural Consequences  Aerodynamic Forces on bodywork, wings, …  Simulate Deflection  ‘Calibration’ on real car – Rather than ‘delaminating’ & testing materials – ‘Fish weighing scale’  Manual input in Pro/Mech : Surface regions  Holland Engineering Consultants – HEC – Automatic link : EFD – Pro/Mech WF IV

62. EFD – Pressure

63. EFD – ‘Calibration’

65. EFD – Pressure

66. EFD – Pro/MECHANICA

72. Questions? Important dates : -Belgian Champ Car Grand Prix, Zolder, June 1 st 2008 -Dutch Champ Car Grand Prix, Assen, September 14 th 2008