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STAR-CCM+ Accuracy in Vehicle
Aerodynamics Studies
Contents

Basic Process and Validation

Trend Studies for Parts and Modifications

Potential Aerodynamic and Cooling study with same Model
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Process Overview
STAR-CCM+ is an environment that provides the
tools to go from CAD to report of results.
Automation: Define pipeline for process
- Flexible to meet our clients needs.
- Minimizes User Interaction
Wrapper Remesher
Surface
Preparation
VolumeMesh
Generation
Hexahedral
Mesher
Prism
Layer
Solver
Post
Processing
Solver
Key Point: Automatic Meshing for Complex Geometry
Model Attributes
4
ASMO Body
Wind Tunnel
6
CFD
Example of Separation Off of Rear Glass
When it becomes to prediction of separation, best
results have been obtained using a Two Layer wall
model. Flexibility of STAR-CCM+ allow for grid
generation with Y+ of 1, transitioning outward to
the far field.
2-Layer
SSTk-w
Experiment
k-e
Separation off of Tire: Low Reynolds Mesh
1 Accuracy: Stationary vs. Rotating Tires
Good reference: SAE 2007-01-0107
The Influence of Rotating Wheels on Vehicle Aerodynamics
Numerical and Experimental Investigations
Alexander Waschle, Daimler, AG

STAR European Conference 2009 8
Combination of Vehicle Studies
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0.003
0.004
0.005
0.006
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STAR-CCM+ vs Experimental Data
Net Difference in Drag Coefficient
Drag Trend: Comparison of Drag for vehicles with
increased blockage area.
Note:
Analysis compares CFD simulating open road compared to open cross section
wind tunnel.
Drag Trend: Effect of large/small spoilers on a sedan
Note:
Analysis compares CFD simulating open road compared to open cross section
wind tunnel.
Trend prediction: Spoiler modification on a sports car.
Benchmark showing modifications to front/rear
spoilers, and the trend compared to a baseline
analysis.
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-0.025
-0.020
-0.015
-0.010
-0.005
0.000
0.005
0.010
0.015
Case 1 Case 2
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Front/Rear Spoiler Modifications
Experimental Data
STAR-CCM+
Code 2
Code 3
Trend Prediction: Examining front/rear spoilers affect on
vehicle lift components on a Sedan
Baseline
Rear Spoiler
Front Spoiler
Study showing experimental data compared to STAR-CCM+ when
adding front and rear spoilers to an existing baseline analysis.
Trend in Drag: Underbody Modifications
StandardSpoiler
ModifiedSpoiler UnderbodyofStandardSpoilerandmodifiedSpoiler
Undercover
Undercover
Undercover
Withoutundercover3 Withoutundercover3and2 Withoutundercover3,2and1
Withall
Addfloorcover
StandardSpoiler
withoutundercover3
StandardSpoiler
withoutundercover3and2
StandardSpoiler
without3,2and1
Shapeofaddedfloorcover
BaseModelbase
ModifiedModel
UnderPartsModificationPattern
Replacecoverparts,StandardSpoilerCase1isthebase.
case3 case4 case5 case6
case1
case2
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Trend in Drag: Underbody Modifications
Example showed multiple modifications to underbody.

Aerodynamics and Cooling
Our numerical models for Vehicle Thermal Analysis and
our models for Aerodynamics (open grill) are very similar
only difference is local refinement
For most passenger car development Aerodynamics and
Engine cooling /Thermal protection are done by different
departments
We have seen for Commercial Vehicles (Trucks) combined
Aero/Cooling models developed
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Typical Aero model (open grill) suitable for cooling study
LowReynoldsmesh
onExterior
HighReynoldsmeshin
EngineCompartment
Page 18
Heavy Truck
Delivery Van
Cooling Drag
Cooling Drag=Cd(Open) - Cd(closed)

Client was having problems with
competitor codes under predicting
cooling drag and used STAR-CCM+
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-0.040
-0.035
-0.030
-0.025
-0.020
-0.015
-0.010
-0.005
0.000
0.005
0.010
Case 1 Case 2
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Cooling Drag
Experimental Data
STAR-CCM+
Code 2
Code 3
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Drag Prediction Best With Low Reynolds K-SST
(Answer within 3-8 Points)
Conclusionfromstudy:
LowReynoldsmeshwithK-omegaSST
modelprovidedmostaccurateresults.
Resultswereasgoodifnotbetterthenthe
competitorscode.
Accuracyandease-of-usedroveFiatto
quicklychooseSTAR-CCM+astheir
choiceforVehicleAerodynamics
Comparison of Audi Wake
YourPartnerForSuccess
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