Development of a CAE Method to Predict Damage to Underfloor Components in Flooded Roads

Hidenori Mayusumi･Jun Miyazaki･Kei Akasaka･Kosuke Nakasato (Nissan Motor)

In recent years, with the electrification of vehicles, plastic covers have been increasingly used in the underfloor area. While driving on flooded roads, the underfloor components of vehicles are subjected to water pressure. These parts must be designed to withstand this pressure without damage. To shorten the vehicle development period and reduce costs, CAE analysis is effective in the design phase. Therefore, we developed a CAE method that evaluates the risk of part damage by coupling fluid analysis using a particle method with structural analysis.

Investigation of the Flow Separation from the DrivAer Notchback Rear Window with DDES and LES

Luca Bauer (Technical University of Munich)･Jonas Sebald (Audi)･Philipp Schlichter･Thomas Indinger (Technical University of Munich)

Computational Fluid Dynamics (CFD) workflows that employ Delayed Detached Eddy Simulation (DDES) typically provide accurate predictions regarding automotive external aerodynamics. However, DDES can exhibit inaccuracies in specific regions of the flow field. This study examines one such critical area: the boundary layer separation from the rear window. Therefore, we benchmark both DDES and Large-Eddy Simulation (LES) against wind tunnel data for the DrivAer Notchback by using an OpenFOAM workflow.

Numerical Investigation of Water Flow in Narrow Gaps of Vehicle Interior Components

Evelyn Sabella Rugerri (Technical University of Munich)･Dirk Baeder (Audi)･Thomas Indinger (Technical University of Munich)

If one unintentionally spills beverages or keeps the sunroof open during a rainy day, several electronic and mechatronic components may be exposed to water. Hence, monitoring water in vehicle interior is part of a growing body of research on water management. This study bridges the physical insights to its virtual representation using a novel Lagrangian 3D-CFD solver. Despite its flexible nature, the computational time for simulation on complex geometries still seeks great optimization. This is to be conducted by means of a mathematical modeling of flows in narrow gaps, whereas the models are obtained empirically using Design of Experiment (DoE).

CFD simulation of BPE on a drum brake

Shuhei Tanamachi･Taisuke Ito･Katsuhiro Uchiyama･Yoshiyuki Yamaguchi (Nisshinbo Brake)

Wear dust particle emissions from automotive brake friction materials are subject to EURO 7 regulations and are an important factor to be considered in the design of friction materials. This study focuses on the particle emissions of drum brakes and presents the results of a CFD simulation parameter study. The actual test results showed similar trends to the simulations.

Numerical Implementation of a Leak Testing Method to be applied to High Voltage Batteries

Matthew Sleight･Stefan Adami (TUM)･Mathieu Mulmann (Audi)･Thomas Indinger (TUM)

The production of High Voltage batteries is a major challenge for the automotive industry. To improve battery production quality, optimizing the leak test would be an important development. This test consists of changing the pressure in the battery and measuring the volume leakage. To do this, CFD simulations are carried out using the SPH method. A numerical model is used to reproduce the different phases of this test. These results are compared with experimental data. The recreated process will help to optimize the process thanks to a better understanding of the phenomenon.

CFD Methods for the Predection of Washer Fluid Behavior during Wiper Operation

Shun Nakamura･Yuta Ito･Arisa Mizutani･Shiro Yasuoka (Toyota Motor)･Gabriel Pichon (Dassault Systems)

A CFD analysis using the LBM coupled with a Lagrangian particle tracking was developed to predict the washer fluid behavior during wiper operation while driving.
This presentation compares the simulation results with the experimental data and shows the development approach with this method.