Aerodynamics

Division Overview

The Aerodynamics division is responsible for designing, analyzing, manufacturing, and validating the aerodynamic package of our teams FSAE vehicle. This includes the development of components such as the front wing, rear wing, undertray/diffuser, composite body, and powertrain cooling. Members in the division learn and work with CAD, CFD, FEA, composite manufacturing and full-car performance analysis to drive their designs, improve downforce generation, aerodynamic balance, drag efficiency, and overall vehicle performance. Our division is ideal for students interested in fluid mechanics, vehicle dynamics, simulations, composite manufacturing and race car design.

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Components

1. Front Wing:

   
   

   • Directs airflow around the car

   • Increases grip when cornering

   • Improves overall stability

     
     

2. Rear Wing:

   
   

   • Generates strong downforce

   • Keeps the car on the floor at high speed

   • Balances front and rear aerodynamics

     
     

3. Undertray:

   
   

   • Maximizes ground effect

   • Reduces drag for efficiency

   • Enhances handling and performance

     
     

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Software

• Computer-Aided Designs (CAD): SolidWorks

• Computational Analysis (FEA/CFD): Ansys

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Requirements/Characteristics

• Knowledge of CFD and FEA

• SolidWorks skills

• Initiative Preferences: INGE 4016, experience in structural design

Recommended Courses

• INGE 4015: Fluid Mechanics

• INME 4015: Heat Transfer

• INGE 4019: Mechanics of Material

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Division Knowledge Guide

In Formula SAE, Aerodynamics focuses on balancing drag and downforce to maximize performance. Drag is the resistance of air against the car; it generally affects top speed and efficiency, but on the other hand, it comes with useful stability. Downforce is lift in the negative direction (often referenced as left), pushing the tires into the track, improving braking, cornering, and grip. The Reynolds number (Re) is a crucial factor in aerodynamics, indicating whether airflow is laminar or turbulent. For FSAE terms, Re typically falls at low speeds, operating within the range of 105 to 106. This value impacts wing design, influencing the characteristics of the airflow in it. It is very important to highlight the atmospheric pressure and temperature for aerodynamic effects, because cold air is denser, meaning aero performance increases, and vice versa in hot and thin air.

The center of pressure (CP), defined as the point where the total force of pressure acting on an object, must be placed behind the Center of Gravity (CG), the balance of an object, for stability purposes. Designing new components usually follows a workflow of CAD modeling, CFD Analysis, mesh verification, and on-track testing. A reliable CFD can still be achieved by simplifying geometry, using symmetry, and choosing robust turbulence models. The key aero coefficients are drag and lift/downforce, which can also be explained through Bernoulli’s Principle. This principle can work in the optimization of undertrays and diffusers for high downforce with minimal drag, especially for adjustments when the driver experiences oversteer (rear tires lose grip before front tires, causing a spin) at high speed. This can be done by delaying boundary layer separation with multi-element wing slots and selecting proper turbulence models to predict flow separation accurately.

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