STAR European Conference 2010 - MDXmdx2.plm.automation.siemens.com/sites/default/... · Audi R8 GT3...
Transcript of STAR European Conference 2010 - MDXmdx2.plm.automation.siemens.com/sites/default/... · Audi R8 GT3...
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STAR European Conference 2010
AERODYNAMICS DEVELOPMENTS
ON A LE MANS PROTOTYPE
ORECA 01 LMP1
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1. ORECA Presentation
2. Why we use CFD?
2009 Aero Development
2010 Aero Development
3. Methodology
Correlation
Case Studies
Mesh
Results
Conclusions
PRESENTATION
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ORECA:
Since 1972
180 People
35 to 40 Millions Euros / year
4 divisions:
Engine department (Magny-Cours)
Marketing + Incentive
Race parts + accessories sales
Race team + Chassis Engineering
1. ORECA
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ORECA:
RACE TEAM:
Endurance Racing (LMP1 – 2 cars)
Audi R8 GT3 (French GT – 2 cars)
Formula Le Mans
Other projects (engineering / production)
Engineering:
11 Engineers
Aero-group : 6 engineers, 4 working on Star-CCM+
1. ORECA
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2009 CFD Development
We used CFD for :
- Comprehension of LMP aerodynamics- Keep the development of aero-package up through the season
We chose Star-CCM+ for :
- Only one interface- Ratio simplicity / accuracy / cost- Evolution of the Software through the year
2. Why we use CFD?
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2009 Aerodynamic Development:
Oreca 01 :
• Adapt to new ACO Aerodynamics rules (reduction of the rear wing dimensions)
• New aero-package for Courage LC70E LMP1
Tests : ~80% Wind tunnel, ~20% CFD
• 320 runs using a 40% scale model in ACE wind-tunnel (Magny-Cours).
• CFD development : 1 engineer (1 Workstation) working on Star-CCM+ / +80 simu.
2. Why we use CFD?
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2009 CFD Development
History
ORECA 01 V1: introduced in 1000 km Spa (May 2009)
ORECA 01 V2: introduced in 1000 km Silverstone (Sept. 2009). Developped 100% using CFD.
Increasing Efficiency and Downforce
95
97.5
100
102.5
105
107.5
110
112.5
115
2008 car 2008 car +
2009 wing
ORECA 01
V1
ORECA 01
V2
Efficiency
2. Why we use CFD?
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2. Why we use CFD?
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2. Why we use CFD?
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1,5
0,082
-0,141
-0,916
-1
0
1
2
3
4
5
6
7
Race1 Barcelone Race2 Spa Race3 Algarve Race5 Silverstone
Qualifying performances Le Mans Serie 2009
ORECA 01 Position
Aston Position
2. Why we use CFD?
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2010 Aerodynamic Development:
Oreca 02 :
• New LMP1 car designed to compete for 24H of Le Mans (2011) with Peugeot Engine
Tests : ~20% Wind tunnel, ~80% CFD
• CFD development : 4 engineers on Star-CCM+
• 4 Workstations, 1 Cluster of 128cores / 130 simulations in 1,5 month
Why we use more CFD in 2010?
Ratio Cost / Efficiency
Understanding the phenomena and not iterating mechanically
Aero development through the year
Investment : cluster and SKILL
New skills = new business opportunities
2. Why we use CFD?
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Methodology:
Correlation
Straight-Line Test with the real Car
Lift : calculated with Loadcells on each suspension + Pitot sensor
Constant speed
Drag : Coast-down.
All the values are stored in a PI Data Analysis System:
- 4 Loads
- Aero Speed
- Ride Heights Front and Rear
- Acceleration X, Y, Z
- Ground Velocity
3. Methodology
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Methodology:
Case Studies
Straight-Line
Half-car with different Ride Heights
Yaw / Roll
Full car with Yaw, Roll, Steering Angle
3. Methodology
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Slipstream
3. Methodology
DRAG LIFT EFFICIENCY
LEADING CAR FOLLOWING CAR
BALANCE
LEADING CAR
FOLLOWING CAR
Fro
nt
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Mesh / Solver
Mesh : Wrapper + Trimmer + Prism Layer
From 12M, up to 45M of cells
Physics :
- Steady cases
- Unsteady : coming soon...
- Porous Region for Radiators
- Velocity specification on wheels and Floor
- RANS + SST K-Omega
3. Methodology
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3. Methodology
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3. Methodology
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Results
90% of the post-treatment is automated:
Scenes – Starview files
Analitic Results : force reports, mass-flow
Force and Mass-flow reports automated by Java macros
All Results compiled in Excel File
3. Methodology
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3. Methodology
Results - Starview
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3. Methodology
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3. Methodology
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3. Methodology
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3. Methodology
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3. Methodology
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3. Methodology
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Results – Analytic
By macros, we export analytic results:
– Forces on each parts
– Mass Flow : brake ducts, radiator
– Flow around the underfloor : velocity, pressure, angle
– Plots of Coefficient of Pressure : Rear Wing, Front Wing, Undefloor, Diffuser
3. Methodology
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3. Methodology
– Forces on each parts
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3. Methodology
23%
43%
39%
17%
-19% -1% 0% -1%
-30%
-20%
-10%
0%
10%
20%
30%
40%
50%
Win
g
Fro
nt S
plit
ter
Fla
t B
ott
om
Diffu
ser
Bodyw
ork
Fro
nt W
heel
Rear
Wheel
Inte
rnal
SCZ
17%19%
9%
13% 11%
3%
8%
20%
-30%
-20%
-10%
0%
10%
20%
30%
40%
50%
Win
g
Fro
nt S
plit
ter
Fla
t B
ott
om
Diffu
ser
Bodyw
ork
Fro
nt W
heel
Rear
Wheel
Inte
rnal
SCX
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3. Methodology
– Flow around the underfloor : velocity, pressure, angle
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3. Methodology
– Plots of Coefficient of Pressure : Rear Wing, Front Wing, Undefloor, Diffuser
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Conclusions
Since 2 years, ORECA has invested a lot to increase its know-how,methodology and tools to carry extensive Aero development programs onLe Mans Prototypye. We started from Zero and have now an efficientaero-group. Our staff is on a steep learning curve.
The effort we have put in the Aero development started to pay off at the end of the 2009 season. We expect a bigger gain to come with the new LMP1.
We open with the CFD new business opportunities
Our aim is to fight with factory Teams in 2011.
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Special Thanks to
Vincent Keromnès, Christian Fauchier, Christophe Gayet from CD Adapco France.
ORECA’s technical partners: CD Adapco, Dassault System, Araldite, MSC Software.