Vehicle aerodynamics are paramount in enhancing a car's dynamic behavior, boosting performance, and slashing fuel consumption. This paper demonstrates the advanced morphing and optimization capabilities of DEP MeshWorks©, coupled with LS-OPT© and LS-DYNA© ICFD solver, to reduce the aerodynamic drag coefficient of a sports car. Using a CAD model resembling a sports car, the study achieved a 2% improvement in drag coefficient, showcasing significant fuel efficiency gains.

• Objective: Reduce the drag coefficient (Cd) for improved fuel efficiency and performance.
• Technologies Used:
  • DEP MeshWorks©: Advanced morphing and parameterization.
  • LS-OPT©: Design of Experiments (DOE) and optimization.
  • LS-DYNA©: ICFD solver for aerodynamic simulations.
• Results:
  • 2% improvement in Cd (from 0.660 to 0.648).
  • Drag force reduction from 711N to 698N.
  • Insightful parameter sensitivity analysis.

• Model Preparation:
  • CAD model processed in DEP MeshWorks© for cleaning and simplification.
  • Skin mesh creation for ICFD with quality metrics (aspect ratio ≤ 6).
• Optimization Workflow:
  • Advanced morphing applied to key design regions (spoiler, rear glass, winglets).
  • DOE with 55 designs sampled in LS-OPT©.
  • CFD simulations using LS-DYNA© with LES turbulence model.

This study demonstrated the capability of DEP MeshWorks©, LS-OPT©, and LS-DYNA© to optimize the aerodynamic drag coefficient of a sports car model. Achieving a 2% improvement in Cd within a short optimization cycle highlights the potential for these tools to address real-world engineering challenges under tightening environmental and performance constraints.

The demonstrated workflow showcases a powerful approach to rapid design changes and aerodynamic optimization, making it invaluable for automakers seeking to improve fuel efficiency and reduce emissions.