Aerodynamic Optimization of Passenger Vehicles Using Wind Tunnel Testing and CFD Simulation

Rohan Mehta, Dr. Vivek Sharma

Department of Automotive Engineering, M.S. Ramaiah University of Applied Sciences (RUAS), Bangalore

1. Abstract

Aerodynamic optimization of passenger vehicles represents a significant engineering challenge focused on decreasing drag, boosting fuel efficiency, enhancing stability, and reducing environmental impact. As energy efficiency and electrification gain prominence, the role of vehicle aerodynamics has become increasingly crucial. This research article offers an in-depth examination of aerodynamic optimization for passenger vehicles by integrating Computational Fluid Dynamics (CFD) simulation with wind tunnel testing. It covers theoretical principles, numerical modeling methods, experimental validation, and optimization strategies applied to vehicle designs. A systematic approach is outlined, encompassing geometry modeling, mesh creation, turbulence modeling, simulation setup, wind tunnel testing, and result validation. A comprehensive system design is crafted to merge digital simulation with physical testing in a repetitive optimization cycle. The implementation process illustrates how CAD models are adjusted and optimized based on drag coefficient (Cd), lift coefficient (Cl), and flow visualization metrics. The findings reveal a strong correlation between CFD and wind tunnel experiments, with discrepancies generally ranging from 2–7%, affirming the dependability of hybrid optimization methods. Techniques such as shape alteration, the addition of aerodynamic devices, and underbody modifications substantially decrease aerodynamic drag and enhance vehicle performance. The paper concludes that the combined CFD and wind tunnel method offers a robust framework for effective aerodynamic optimization of passenger vehicles, resulting in lower fuel consumption, enhanced driving stability, and reduced emissions. Future research avenues include optimization based on machine learning, morphing body designs, and real-time adaptive aerodynamics.

2. Keywords

Aerodynamic enhancement; Cars for passengers; Testing in wind tunnels; CFD (Computational Fluid Dynamics); Coefficient of drag; Coefficient of lift; Simulation of flow; Design of vehicles; Modeling of turbulence; Aerodynamics in automobiles.