Aerodynamics

Division Overview

The aerodynamics division is responsible for designing and conducting structural analyses of the vehicle’s aerodynamic package, which comprises the front wing, rear wing, and undertray. Using Finite Element Analysis (FEA) and other computational methods, the team optimizes each component to balance downforce, reduce drag, and enhance vehicle stability through simulations. Once the aero package is designed, the division oversees the manufacturing to ensure precision and reliability. The final step involves testing and data collection, where real-world performance is validated and improvements are identified for the next iteration of the car. 

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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

• INGE 4015: Fluid Mechanics

• Knowledge of CFD and FEA

• SolidWorks skills

• Initiative Preferences: INGE 4016, experience in structural design

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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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