A STUDY OF AERODYNAMICS FOR F1 IN SCHOOLS
MOHD FIRDAUS BIN AB RAZAK
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ii
DECLARATION
“I hereby, declared this thesis entitled
‘A STUDY OF AERODYNAMICS FOR F1 IN SCHOOLS’
is the results of my own research except as cited in the references”.
Signature : .................................
Author’s Name : MOHD FIRDAUS BIN AB RAZAK
Date : 10th May 2009
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To my beloved parent and to the one who willing to seek the knowledge
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ACKNOWLEDGEMENT
The author would like to take this opportunity to thank to his supervisor, Mr.
Mohd Afzanizam bin Mohd Rosli with his guidance and support throughout the
study. Co-operation given by Mr. Razmi bin A Razak and Mr. Kamarudin bin Abu
Bakar from Faculty of Mechanical Engineering technicians, and also to the UTeM’s
Library, the author like thank for the co-operation and supports. Appreciation for the
presentation panels with though, recommendation and encouragement.
Useful information and with raw material from F1 in Schools Sdn. Bhd.
representative, Mohd Nazrin Bin Zulkifli was much appreciated. Participators from
Central North and Central South, especially from KISAS team for willingness to
share experience during the race day.
To the family and friends, the author would like to thank for the supports. To
the Almighty, with the blessing, the author able to finish this study completely.
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ABSTRACT
In this study, aerodynamic characteristic of the Formula One in Schools car
where analyzed by using Computational Fluid Dynamic (CFD) and Wind Tunnel
testing. CFD was capable to analyze the aerodynamic forces of the F1 in Schools car
by obtaining drag coefficient and lift coefficient. Wind tunnel experiment was done
to compare data with CFD simulation. The wind tunnel test may obtain similar
aerodynamic forces from CFD. From the comparison, this study can be verified.
Several models were designed and current model which was used in Wind Tunnel
experiment were modified to see the differences of aerodynamic characteristic. The
final design has low drag coefficient which was positive value approaching to zero
and low lift coefficient which was negative value approaching to zero. The suitable
drag coefficient for F1 in Schools car development is below 0.4 approaching to zero,
while for lift coefficient is above -0.1 approaching zero. This study gives better
understanding about the effect of aerodynamic to “F1 in Schools” cars.
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ABSTRAK
Dalam kajian ini, sifat-sifat aerodinamik sebuah kereta “Formula One in
Schools” dapat dikenalpasti dengan menggunakan “Dinamik Bendalir Berkomputer”
(CFD) dan Ujian Terowong Angin. CFD berpotensi untuk menjalankan analisis daya
aerodinamik bagi kereta “F1 in Schools” dengan mendapatkan nilai bagi pekali
seretan dan pekali daya angkat. Keputusan dari eksperiment Terowong Angin turut
mendapat keputusan yang sama bagi daya aerodinamik daripada analisis CFD.
Daripada perbandingan ini, kajian ini dapat disahkan. Dalam kajian ini juga turut
merekabentuk beberapa buah model dan model sedia ada yang digunakan di dalam
eksperiment terowong angin telah diubahsuai bagi bertujuan untuk mengetahui sifat-
sifat aerodinamik dan perbezaannya. Pekali seretan yang sesuai bagi merekabentuk
kereta “F1 in Schools” ialah kurang daripada 0.4 dan menghampiri kosong, manakala
bagi pekali angkatan ialah lebih daripada -0.1 dan menghampiri kosong. Tujuan
kajian ini ialah untuk memberi penerangan mengenai sifat-sifat aerodinamik
sesebuah kereta “F1 in Schools”.
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TABLE OF CONTENT
CHAPTER TITLE PAGE
DECLARATION ii
APPROVAL iii
DEDICATION iv
ABSTRACT v
ABSTARK vi
TABLE OF CONTENT vii
LIST OF TABLE x
LIST OF FIGURE xi
LIST OF SYMBOL xvii
LIST OF APPENDIX xviii
CHAPTER 1 INTRODUCTION
1.1 Study Backgound 1
1.2 Problem Statement 2
1.3 Objectives of Study 3
1.4 Scope of Study 3
1.5 Benefit of Study 4
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 5
viii
CHAPTER TITLE PAGE
2.2 F1 in Schools 5
2.3 Fundamental of Aerodynamics 7
2.4 Computational Fluid Dynamics 15
2.5 Wind Tunnel Test 16
2.6 Previous Study in Aerodynamics 20
CHAPTER 3 METHODOLOGY
3.1 Introduction 23
3.2 Literature Review 24
3.3 Design Phase 25
3.4 CFD Modeling 26
3.5 Fabrication 38
3.6 Wind Tunnel Test 39
CHAPTER 4 DATA ANALYSIS AND RESULT
4.1 Introduction 42
4.2 Wind Tunnel Result 42
4.3 CFD Analysis 44
4.4 Comparison of Wind Tunnel and CFD
Result
45
CHAPTER 5 DISCUSSION
5.0 Introduction 47
5.1 Source of Drag 48
5.2 CFD Validity Test 48
5.3 Secret Behind the Fastest Car 50
5.4 Modification 51
5.5 Final Design 54
ix
CHAPTER TITLE PAGE
CHAPTER 6 CONCLUSION &
RECOMMENDATION
6.1 Conclusion 56
6.2 Recommendation for Future Studies 57
6.3 Recommendation to Faculty of
Mechanical Engineering, UTeM
58
REFERENCES 59
BIBLOGRAPHY 61
APPENDIX 63
x
LIST OF TABLE
NO. TITLE PAGE
4.0 Wind tunnel result 4
4.1 CFD analysis results 6
4.2 Grid Independence Test (Drag and Lift
Coefficient for 25m/s)
8
5.0 Comparison between Liou, W. W., and Son, H,.
(2003) and Validity Test
9
5.1 Validity test result 10
5.2 Comparison between sleek design and blunt
design
11
5.3 Modification of car model 21
xi
LIST OF FIGURE
NO. TITLE PAGE
1.0 Race day of F1 in Schools
(Source: By Author)
4
2.0 Blank balsa wood
(Source: Rules and Regulation 2008 Season, [10])
6
2.1 Balsa wood after machined
(Source: By Author)
6
2.2 Sample of previous Formula One in Schools
(Source: By Author)
7
2.3 A fluid element passing through “Point 1” in a
flow field
(Source: Anderson, 2007)
8
2.4 Figure 2.2: Aerodynamic forces
(source: http://www.grc.nasa.gov/WWW/K-
12/airplane/presar.html)
9
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NO. TITLE PAGE
2.5 Figure 2.3: (From left) Bernoulli’s, Newton, the
innovation Aerofoil.
(Source: http://www.f1technical.net/articles/10)
11
2.6 Shape of a body causing difference in pressure
drag and skin friction magnitude
(Source: Anderson, 2007)
12
2.7 Type of region in fluid flow around cylinder
(Source: Nishino, T. et al, 2007 [17])
13
2.8 Three type of fluid flow inside boundary layer
(Source:http://www.auf.asn.au/groundschool/umo
dule4.html)
14
2.9 UTeM’s Subsonic Wind Tunnel
(Source:http://www.essom.com/UserFiles/MP130
D.jpg)
17
2.10 Axial Fan speed controller
18
2.11 Force indicator 18
2.12 Load Cell
(Source:http://www.essom.com/UserFiles/MP130
D.jpg)
18
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NO. TITLE PAGE
2.13 Incline manometer 18
2.14 (1) Nozzle, (2) filament and (3) platform
(Source:http://en.wikipedia.org/wiki/File:FDM_by
_Zureks.png)
19
3.0 Flow chart for this project 24
3.1 Gambit Startup window 26
3.2 Gambit window 27
3.3 Solver selection 27
3.4 CAD import 28
3.5 Import IGES File window 28
3.6 Imported IGES file 29
3.7 Move/Copy window 30
3.8 Successfully rotated 30
3.9 Face created 31
3.10 Selected surface for face mesh 31
3.11 Brick created as for test section 32
xiv
NO. TITLE PAGE
3.12 Translated brick 32
3.13 Split the edge to create vortices 33
3.14 Edge created 33
3.15 Symmetry plane component, face A 34
3.16 Symmetry plane component, face B 34
3.17 Connected edges were meshed as edge mesh 35
3.18 Volume selected for mesh 35
3.19 Volume mesh was inspected 36
3.20 Boundary type was set 36
3.21 Export Mesh File window 37
3.22 FDM Machine
(Source: By Author)
38
3.23 Produced car 38
3.24 CAD drawing for RP 38
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NO. TITLE PAGE
3.25 Diagram of wind tunnel load cell, Factual = [D, L],
Findicated = [Do, Lo]
(Source: Subsonic Wind Tunnel Manual
Instruction)
39
3.26 Model setup and direction of the load cell
(Source: By Author)
41
4.0 Coefficient of Drag for Car Model 45
4.1 Coefficient of Lift for Car Model 46
5.0 Aerofoil grid 49
5.1 Velocity contour for 0 degree angle of attack 49
5.2 Pressure contour for 0 degree angle of attack 49
5.3 Velocity contour for 3 degree of angle of attack 50
5.4 Pressure contour for 3 degree of angle of attack 50
5.5 FUGA 51
5.6 Modification 1 52
5.7 Modification 2 52
5.8 Modification 3 53
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NO. TITLE PAGE
5.9 Modification 4 53
5.10 PULSE, the 2008 International F1 in Schools
Champion and Fastest Car
(Sourse: http://www.pulsef1.co.uk)
54
5.11 Final design 54
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LIST OF SYMBOL
A = Projected Area
Cd = Drag coefficient
Cl = Coefficient of lift
D = Drag force
Do = Indicated Drag Force
l = Length
L = Lift force
Lo = Indicated Lift Force
ρ = Density
Re = Reynolds number
τij = Stress tensor
µ = Dynamic viscosity
v = Kinematic viscosity
V = Velocity of fluid
x = Distance/length
�� = Actual distance
�� = Standard distance
xviii
LIST OF APPENDIX
NO. TITLE PAGE
A Rules and Regulation for Formula One in Schools Car
Development
63
B Car Model for Wind Tunnel
68
C Wind Tunnel Experiment
70
D Modification 1
72
E Modification 2
74
F Modification 3
75
G Modification 4
76
H Final Design 77
I FUGA 78
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CHAPTER 1
INTRODUCTION
1.0 Study Background
When the F1 in Schools’ cars were launched, the speed was build up rapidly
due to thrust which was caused by CO2 pressurized cartridge. This is similar to a
bullet fired from a rifle. The speed was believed to be exceeding 70km/h or 19.44m/s
at the early stage of the launching. Due to aerodynamic effect, the car tends to slow
down at the end of the finish line which gives different time record [5].
It is obvious that the car with better aerodynamic shape is faster than a car
with blunt shape. These because of air resistance occur while the car is moving along
the track. The external flow of air around the cars can be determine by wind tunnel
experiment, calculation and computerized solving which is known as Computational
Fluid Dynamics (CFD) [6].
From the usage of CFD, the car can be design effectively in order to achieve
better aerodynamic properties like low drag and low downforce. The CAD model can
be tested without the physical model or prototype. The model has to be meshed
before it can proceed to CFD analysis. However, CFD analysis has quantized error
due to numerical iteration and the choices of turbulence model. The CFD analysis
can be verified with wind tunnel experiment and calculation [16] [21].
Wind tunnel test is performed and the actual condition of the car can be
monitor. This test is quite complex and time consuming. For this study, the prototype
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had to be prepared by using Rapid Prototyping machine. The 3D model used in CFD
may also used for Rapid Prototyping process.
From the wind tunnel result, CFD setting shall be adjusted to gain similar
result from the wind tunnel. Further study of aerodynamics can be proceeding as
suitable setting obtained. The aerodynamic characteristic can be determine and can
gives better understanding of the design consideration of a Formula Student in
Schools car.
1.2 Problem Statement
The aerodynamics study about the F1 in Schools is quite interesting because
slight changes and differences may cause the performance of the car same as real F1
cars. Many of the contestants from the school within Malaysia did not have proper
data and analysis to investigate the effect of the aerodynamics. Past two year,
Malaysia team from SMK Convent Bukit Nanas had awarded third place, afterward,
no other Malaysian team can go further [5]. These may because of improper analysis
for the building of the cars.
• Mostly the student designed the cars with ecstatic element rather than
aerodynamic efficiency.
• Majority of them use basic shape and with small modification for
better look.
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1.3 Objectives of Study
From the problem statement, the solution has been planned and the objectives
for this study were set. The objectives of this project are:
• To study the effect of aerodynamics in “F1 in School” cars.
• To provide a systematic research about the aerodynamic.
• To compare the designed “F1 in School” car with the fastest car as a
benchmark which was recorded in 2007 International Finals.
• To fabricate the designed car.
• To perform the wind tunnel test.
• To run CFD simulation for modeled Formula One in Schools cars.
1.4 Scope of Study
The main objectives of this research are to make analysis about the
aerodynamic effect on “F1 in School” cars and then to fabricate them. This project
will covers from:
• Designing: design consideration about feature in real F1 cars, specification
studies given by the organizer, manufacturing considerations are taken into
account, design concept and 3-dimension modeling. 3-dimension modeling of
previous world record holder shall be made. The software used for 3-
dimension modeling is CATIA V5R10
• CFD Analysis: Aerodynamics analysis will be the main analysis for this
research. The aerodynamics analysis may cover entire part of the cars
including bodywork and wheels. This project may use CFD software for
aerodynamics simulation and detailed analysis. The software used for CFD
analysis is Fluent 6.2.
• Fabrication: Rapid Prototyping used for fabricate a model for wind tunnel
testing.
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• Wind Tunnel Testing: After fabrication has completed, wind tunnel analysis
will proceed. Wind tunnel used for this study is UTeM’s subsonic wind
tunnel.
Element that may not be covered in this project are:
• Material analysis such as stress analysis shall not be covered.
• Surface finish may not be cover in this study because of expensive materials.
• Ecstatic element will not be included in this research.
1.5 Benefits of Study
The CFD and wind tunnel analysis may able to clarify and gives better
understanding for the student about the importance of aerodynamic effect. It also
gives the reader an idea to overcome the drag force and also low in negative lift
force.
From this report, hopefully this project may give them (participating school)
a guide line for design consideration and better analysis the main element in “F1 in
School”.
Figure 1.0: Race day of F1 in Schools
(Source: By Author)
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
In this chapter, all terms in this study shall be defined and some explanations
of the term may take place. This chapter may discuss about the “F1 in Schools”, the
definition of aerodynamic, the CFD usage and application, fabrication and wind
tunnel test.
2.2 F1 in Schools
“F1 in Schools” was founded in 1999 by Andrew Denford. “F1 in Schools”
first established only at United Kingdom during year 1999 until 2003. In 2004, the
“F1 in Schools” was introduced to many countries across the globe and accepted
widely. The “F1 in Schools” competition is about 3 years old in Malaysia. During the
first year in 2006, Malaysian team managed to get the “Fastest Car” award and break
the record which was 1.083 second [5].
“F1 in Schools” is a small car made from Balsa wood which is light weight
wood [18]. The used of balsa wood is suitable for “F1 in School” because the density
of the balsa wood is around 100 to 200 kg/m3 or typically 140 kg/m
3 which is 1/3
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less density of hard wood. The main driver of the “F1 in School” is compact
compressed reclaimed CO2 power plant. The six elements for “F1 in School” are;
business plan for acquiring sponsors, designing using CAD, analysis using CFD,
fabricating using CNC machine, wind tunnel testing, and race [5].
Figure 2.0: Blank balsa wood
(Source: Rules and Regulation 2008
Season, [10])
Figure 2.1: Balsa wood after machined
(Source: By Author)
Competitors came from all over the world has to compete in national stage
before selected to represent for their country. All of them using same rule and
regulations and the criteria for marking such as specifications, design portfolio, team
design for F1 cars, used of CAD and ICT, and quality of manufacturing [5].
The interesting is, the main factor which can make the car be a fastest car is
the aerodynamic of the car. The car which can cut the air smoothly through the
straight line about 20 meters (m) can become the fastest car. In the “F1 in School”
track record hold by Team Fuga from Northern Ireland in 2007 at Melbourne
Australia venue. The time recorded is 1.020 second (s) [5]. The velocity of the car is
19.608 m/s which equal to 70.589 km/h.
Basically, the car was placed onto the track and a string will be attached to
the screw pin underneath the car for guidance. The acceleration builds up from the
force generated from CO2 cartridge until the pressure depleted. The cars keep on
cruising until it reached the halting cushion. Each car may give different timing
because the drag produced by each car may different. The possible element that