Aerodynamics
Purpose
The aerodynamics subsystem aims to maximise the car's performance by reducing drag and maximising downforce using aerodynamic components such as the undertray, side stacks and nosecone. Moreover, the manufacturing of body panels falls under the aero teams' responsibilities, which requires inter-disciplinary collaboration with the chassis team and the Design and Marketing teams.
Goals
| Primary Goals |
|---|
| Design and manufacture nose cone, side pods, cooling systems and body panels |
| Research carbon fibre and other composites manufacturing methodologies |
| Secondary Goals |
|---|
| Design and manufacture front and rear wing package |
| Weight optimisation of systems |
Key Components
Given all aero components are built onto the outside of the car the team must work closely with the chassis subsystem as they build the structure that the components attach to. Moreover, all aero works are designed using CAD modelling software in conjunction with the chassis design to optimize all components of the car correctly before manufacturing.
Front and Rear Wings
Front and rear wings generate down-force, which improves high-speed handling and traction. An effective wing package can increase the manoeuvrability of the car. The wings are designed to maximise the lift-to-drag ratio. The front wing is also designed to redirect air above the front tyres. Both components are designed in CAD and then utilised CFD simulations to visualise flows surrounding the vehicle to maximise the previous considerations before manufacturing. Once this analysis has occurred, the moulds are CNC’ed, and carbon fibre layups are completed before mounting to the vehicle.
Undertray and Side Stacks
The undertray is a key aerodynamic component as it brings in the most downforce while reducing the drag on the car. Using the venturi effect, it utilises the space beneath the car to generate downforce with a desirable lift-to-drag ratio. The side stacks are designed to maximise this ratio and redirect air above the rear tyres. Both components are designed in CAD and then utilised CFD simulations to visualise flows surrounding the vehicle to maximise the previous considerations before manufacturing. Like the wings, once this analysis has taken place, moulds are CNC’ed, and carbon fibre lay ups are completed before mounting to the vehicle.
Nosecone and Body Panels
The nosecone is the first point of contact of the car as it travels. A high performance nosecone allows the car to slip through the air. Nosecones can be utilized as aerodynamic devices to redirect air over the driver, under the car towards the undertray for performance or to the sidepods to improve cooling. In addition to body panels, the nosecone is also the predominant location for sponsorships and the car’s design livery. These components also protect the driver from debris from the track. Carbon fibre parts can be made using a variety of methods, from wet layup to resin infusion. Panels can be made flat, or complex using moulds that are manufactured from timber, foam or fibreglass. Finally, the components are attached to chassis in compliance with FSAE regulation.
Cooling and Side Pods
The cooling system falls under the responsibility of the aerodynamics team. Cooling is typically housed in the side pods, and serves to ensure that the motors and inverters remain in a safe operating temperature. The cooling system is essential as it allows the car to operate for extended periods of time. Cooling engineers need to calculate thermal requirements of the components within the system. An application of thermodynamics is key to understanding how much heat needs to be dissipated, especially in difficult environments like Australian summers. Fluid dynamics knowledge is used two fold in cooling applications, first ensuring sufficient pressure is provided by the cooling pumps to circulate coolant through the system, second ensuring optimal cooling performance is achieved by the radiators by having enough airflow through them.
Side pods are often used to house cooling, but can also function to redirect air in numerous beneficial ways such as reducing tire squirt, sealing the under-tray for increased performance or redirecting air to the rear wing.
Future Research Projects
Aerodynamics can be manipulated with winglets and other vortex generators to improve performance in other complex methods. This includes directing air away from tires which generates a large turbulent wake on its trailing edge, a phenomena called tire squirt, directing the squirt away from the underbody can decrease drag and improve vehicle efficiency. Further optimisation and research into the ground-effect is just one aspect of the aerodynamics subsystem’s responsibilities.
Industry and Work Opportunities
Aerodynamics and fluid dynamics are a massively expanding aspect of the engineering industry. Improving aerodynamic efficiency is often seen in COD (coefficient of drag) of electric vehicles. Many motorsports such as Formula 1 and MotoGP focus massively on aerodynamics to find competitive advantages. Further applications of fluid dynamics include aerospace engineering, the energy sector, civil engineering and plant process engineering.
Materials and Manufacturing Exposure
| Materials |
|---|
| Carbon Fibre |
| Fibreglass |
| Kevlar |
| Epoxy Resins |
| Epoxy Hardeners |
| Timber |
| Manufacturing |
|---|
| Composites Wet Layups |
| Composites Resin Infusion |
| CNC Machining |