Breaking Records using Digital Aerodynamic …star-global-conference.com/sites/default/files/public_pdf... · Mercedes-Benz has a Unique Heritage –also in Aerodynamics History of

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Breaking Records Using Digital Aerodynamics Development:

The Mercedes-Benz Concept IAA

Star Global User Conference Berlin 2017

Dr. Erich Jehle-Graf, Daimler AG

Content

1. History of Mercedes-Benz Aerodynamics

Development

2. Tools in MB-Cars Aerodynamics Development

3. Aerodynamics CFD Process

4. The Aerodynamics Car Development Process

5. Actual Aerodynamic Features on MB Production

Cars

6. Future Concepts in Car Aerodynamics

7. Development of the Concept IAA

Dr. Erich Jehle-Graf, Daimler AG, Star Global User Conference Berlin 2017 2

Mercedes-Benz has a Unique Heritage – also in Aerodynamics

History of Mercedes-Benz Aerodynamics Development


1938: W125 Record Car

cD = 0.16, vmax= 433 kph

1984: 220D (W124)

First Sedan with cD =0.29

1978: C111-III Diesel Endurance

World Record Car

cD=0.18

vaverage =316 kph

1936: W25 Stromlinie

cD = 0.225, vmax= 370 kph (Driver Caracciola on A5)

Tools in Aerodynamics Development Today

Wind Tunnel

Tools in MB-Cars Aerodynamics Development


CFD

TIGStarCCM+

Meshing and Post Processing Is Today Fully Automated in Batch, Driven by the

StarCCM+ Custom Tool Tabular Input GUI (TIG)

5

Aerodynamics CFD-Process

Own Parts

Nastran-files

Scans (Styling)

STL-files

(CAD-POOL)

Smaragd-Data(“Download”)

Data-Filtering

Model-Setup

Post-Prozessing

• Settings are saved in a tigxml-file.

• The settings can be applied on any CAD data set of the same structure

• Meshing, solving and post processing can be started now in batch,

each with one command for one case.

pmlxml-file

bif-files

JT-files

Dr. Erich Jehle-Graf, Daimler AG, Star Global User Conference Berlin 2017

The Standard Aero-Development Process takes 3-4 Years and is an

Efficient Combination of Simulation and Wind Tunnel Testing.

The Aerodynamics Car Development Process


3D-Studies

Proportion Model

“See-Through-Phase”

3 Models 1 Model

Styling Phase

4-16 Models

Sty

lin

g

Pro

ce

ss

Ae

rod

yn

am

ic

Pro

ce

ss

M1to4 Models M1to1 Models

Prototypes

“Styling Freeze”

Job #1

Simulation M 1to1 Wind Tunnel Tests

Morphing

Parametrized

CADFEAFEA

Aero/

Thermo

Aero/

Thermo

NVHNVH

CrashCrash

DOE-Optimization

Model Organization, Meshing, Solving, Post ProcessingStarCCM+ & TIG:


Actual Aerodynamic Features on MB Production Cars

Optimization to the Smallest Detail is the Base for Best Aerodynamics

• Optimized base

shape

• Perfect underbody

including Wheels

2013: CLA Class

Present Aero-Champion cD=0.22

Wheelspoiler

Aero-Covers • High efficient adjustable

cooling system

C-Class

The Challenge: How Far Can We Get with a Full Size Car –

Suitable for Daily Use?

Future Concepts in Car Aerodynamics


„Boxfish on Wheels“:

cD=0,19cD=0,19

Competitors:

Concept

Intelligent Aerodynamic Automobile:

Emotional, sporty Styling

High efficient Aerodynamics cD =0,19

cD=0,25

cD ~0,5

1936 Autobahnkurier (W29)

cD ~ 0.65

1950 Chevy Fleetline Aero

Development of the Concept IAA Was a “Fast Forward” of the

Standard Process: Simulation of Over 300 Variants in 5 Month!

Development of the Concept IAA


cD =0,19

Digital Transformer: Almost Completely Developed with CFD!



Dcw = - 0,015 Dcw = - 0,010 Dcw = - 0,035

Transforming

Features:

Front Flap Rear ExtentionRim Camber

Clean Flow in Aerodynamic Mode,

Vortices and Bigger Wake Structures in Style Mode!



Concept IAA: Aerodynamic-Mode (cD = 0,19)

Concept IAA: Style-Mode (cD = 0,25)


Documents

Breaking Records using Digital Aerodynamic …star-global-conference.com/sites/default/files/public_pdf... · Mercedes-Benz has a Unique Heritage –also in Aerodynamics History of