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CFD simulation model for Formula Student external aerodynamics : design & automation of pre- and post-processing

Suoranta, Panu (2025)

 
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Suoranta, Panu
2025
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-2025060319530
Tiivistelmä
The basis of this thesis is the development of a new computational fluid dynamics (CFD) simulation model for improving the design of aerodynamics for Tampere Formula Student and its cars. The new simulation model should improve on the previous iteration that uses the cloud-based service SimScale and OpenFOAM. Although mostly functional, the old simulation model required more manual input from the user for each simulation that is set up, leading to reduced design time.

The new simulation model was developed using Siemens STAR-CCM+, focusing on creating a template that minimizes the active user time that is spent on setting up preprocessing and collecting post-processing data from the simulation. Automating the process should improve the design workflow by providing more consistent comparisons of resulting data. The simulation setup evolves through three main iterations: a single airfoil, the Tampere Formula Student 2024 car with rotating wheels, and the 2025 car with added porous radiator and
fan.

Automation of preprocessing focused on automatically reading the assembly, part and solid info of the computer-aided design (CAD) models of the car into the CFD setup reducing set up time of the simulation to less than two minutes. Post-processing focused on what an aerodynamics designer needs for reading the effects of new parts on aerodynamic flows and losses. The simulation model automatically exports dozens of angles and pictures of different aerodynamic variables.

The result of the thesis was the reduction in active user time by more than 90%, saving over 100 hours during a single season. The simulation model is ready for more validation using track testing data and remains scalable and parametrized for future improvements.
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