WIND TUNNEL

Research tool used in aerodynamic research-study the effects of air moving past solid objects.

Instead of the air's standing still and the aircraft/vehicle moving at speed through it, the same effect would be obtained if the vehicle stood still and the air moved at speed past it.
Stationary observer could study the aircraft/vehicle in action, and could measure the aerodynamic forces being imposed on the aircraft/vehicle.

Wind tunnels are used to predict the amount of force generated by solid objects. This helps aerodynamicists choose the proper size for things such as wings, spoilers, and parachutes.
Information obtained in wind tunnels is used to improve the design of anything affected by wind.

WIND TUNNEL AUTOMOBILES: To determine not only aerodynamic forces but also to determine ways to reduce the power required to move the vehicle on roadways at a given speed. Unlike Aircraft, the interaction between the road and the vehicle plays a significant role, and this interaction must be taken into consideration when interpreting the test results Moving Belts Approximate the actual condition

Automotive companies employ wind tunnels to analyze their latest models-test an entire vehicle, they will also evaluate the aerodynamics of individual components, such as grilles, side view mirrors, air dams, rear-deck spoilers and roof racks.
In race car industry- Race teams routinely subject scale models to wind tunnel testing as well as full-size cars or individual parts

Wind-Tunnels come in all shapes and sizes Wind tunnels are either open or closed-return. They can have open or closed test-sections where the models are tested. They can be as large as big buildings or fit on tabletops. They use fans, compressors, or high-pressure tanks to move air, or other fluids through the test section. The test sections are round, square, rectangular, or other shapes like hexagonal

EIFFEL TYPE TUNNEL open air return

Takes air from the surroundings & expels it to the surroundings Designed to return the air with the lowest possible losses Operation is dependent upon the weather Air flow in test section free from wind effects More Power Loss Excessive Noise Economical & Simple Construction

 GOTTINGEN TYPE TUNNEL Closed air return

Fan drives the air in a closed circuit Low Power Reduces the Operating Cost Automobile Model - Plastilina Loses its stability at higher temperatures Cooler power loss Air conditioning & Climatic Work

National Wind Tunnel Facility, IITK

Special Capabilities
Important features High Reynolds Number simulation Very low turbulence Interchangeable mobile test sections Automated measurement & control systems Full-model testing with sting support system 2-D model testing using turntables Open jet testing Flow diagnostic using PIV & visualization Ground effect simulation with moving belt Gust and cross-wind simulation ABL simulation for civil applications

WIND TUNNEL CONSTRUCTION ELEMENTS: Determine the Size, Performance & Quality of a Wind Tunnel TEST SECTION NOZZLE & SETTLING CHAMBER FAN & DRIVE COOLER TEST SECTION Determine the Overall Size of Wind Tunnel Governing Parameter -Cross- Section Area of the Wind Tunnel Nozzle AT

Blockage Ratio (BR) should be as small as possible (on the road it should be zero) Aircraft Aerodynamics BR < 0.05 GM Automobile wind tunnel only meet this requirement But Higher BR Automobile Aerodynamics

Open Test Section: Free Jet Air Stream 3 Free boundaries Air from the test stream mixes with the surrounding air as a free jet Limits the usable length of the test section Gradient of the Static Pressure along the Tunnel axis is negligible No errors in measuring drag Drag of longer bodies with large vertical surfaces at the front and rear can be measured without errors Blockage Ratio is less compared to Closed parallel Test Section Easy Accessible Facilitates Experimenting & Photographing the flow Higher Loss coefficient of the free jet unimpeded sound radiation

Closed Test & Streamlined Section: Larger usable length of the test section Air stream is dissipated much more slowly along a closed duct than in open jet Friction loss along the walls Result in a Pressure Decrease along the axis of the stream Pressure Decrease is compensated by slightly widening the tunnel cross section in the flow direction Blockage Value is double of free jet Overcome by the Streamlined walls Frontal Area of Average Passenger Car 1.85 m - Deviation between the large & Small cars is no more than +/- 15% Tunnel Walls are shaped according to the flow pattern of the average car in the open air air flow for smaller & larger vehicles will be slightly distorted

Slotted Wall: Combine the Advantages & Eliminate the disadvantages of open & Closed test sections Water Tunnels & Wind Tunnels in Marine Hydrodynamics Open Area Ratio (free surface to Covered surface) must be calibrated so that the pressure distribution is similar to the open air

VEHICLE SCALING Full-scale testing avoids the scaling problems with models, it requires large wind tunnels and is expensive. Scale model testing, which is comparatively inexpensive and more convenient for shape modifications, is widely used in the development of new products In the United States, for passenger cars 3/8 scale is widely used, while in Europe 1/4 scale is the most common, though 1/5 scale is also used in small wind tunnels For commercial vehicles, a scale of 1/2.5 is recommended

FUSED DEPOSITION MODELING (FDM) FDM is a faster, less expensive and more efficient method for making detailed and accurate test models . FDM materials are some of the strongest available in the additive fabrication market, Polycarbonate (PC), PC-ABS and polyphenolsulfone (PPSF) It can withstand the forces and stresses induced as the air flow strikes the models surface

Model Testing
Problems With Model Testing
Not possible to match Reynolds Number Wind Tunnel cannot reach necessary speeds If it could, Mach number would be too large and wed have to worry about compressibility

Some ways to fix this problem are:

A larger wind tunnel with larger models A different testing fluid with a higher density Pressurizing and/or adjusting the air temp in the wind tunnel Or in our case running the wind tunnel at several velocities and extrapolating to determine useful information.

Basic Problems:

1. Flow Field Similarity: Similarity between the flow pattern in the wind tunnel and that under actual driving conditions on the road Reynolds Number (RN) for the scale model be equal to that for the fullsize vehicle The Reynolds Number is the ratio of the product of airstream speed and the characteristic length of the vehicle to the kinematic viscosity of the air. ( V x Lc /) Flow Field Similarity To satisfy this requirement, a 3/8 scale model should, therefore, be tested in the wind tunnel at an airstream speed of 8/3 of that of the full-size vehicle. Blockage ratio, which is the ratio of the frontal area of the model (or the full-size test vehicle) to the cross sectional area of the wind tunnel test section, should be as small as possible- preferably not exceeding 5%

2.Modeling Of The Ground Plane: When a vehicle is driven on the road at zero wind speed, the air is at rest relative to the road. In a conventional wind tunnel, the air flows with respect to the tunnel floor and a boundary layer builds up. This may significantly affect the flow pattern under the scale model (or full-size test vehicle). To alleviate this problem, a moving ground plane has been used. Air Flow Two Fields one resulting from the forward motion of the vehicle the other from the natural wind Natural Wind Boundary Layer of the Wind is Turbulent Flow Field approaching the Vehicle Largely Inhomogeneous Non Stationary More Complex than that of aircraft Non Homogenous Temperature Field above the road Sunlight will heat the roadway more than the surrounding air

The Experiments
Experiment 1- Surface Pressure measurements Experiment 2- Lift and Drag measurements
Experiment 3- Particle Image Velocimetry, CFD analysis

Results - Pressure

Coefficient of Pressure

Lift and Drag

The model, was connected to a dynamometer that measured force in both the x and y direction, essentially lift and drag. This data was collected using a data acquisition system as well, and processed with a PC. Using these measurements it was possible to calculate lift and drag on the car, as well as lift and drag coefficients.

Source: Brad Bruno

CL

FL

1 ( V 2 A) 2 FD CD 1 2 ( V A) 2

Particle Image Velocimetry

PIV uses the wind tunnel along with a double pulsed laser technique to measure instantaneous velocity and to map out the flow field. This provides a visual representation of the flow along the vehicle, streamlines and a qualitative representation of the velocities.

Source: Brad Bruno

Results - PIV

Flood Contour of Ford NASCAR

Streamline Contour of Ford NASCAR

FLOW VISUALIZATION TECHNIQUES: Visualize the flow on the Vehicle Body Spatial Flow close to the vehicle air flow pattern in the passenger compartment Investigate & Understand the flow field in and around the Vehicle. Flow Pattern adjacent to vehicle body wool tufts Flow Attachment & Flow Separation can be easily detected Surface Oil Film having colored pigments flow separation will not be indicated clearly Smoke Generator Emit Smoke in to the air flow Flow Patterns will be made visible Smoke Generator heating a mineral oil derivative until evaporation occurs dense white inoffensive smoke is provided long thin stem to inject the smoke in to air flow Bubble Generator illustrate the flow pattern in separated flow Helium filled soap bubbles are injected in to the air flow paths are photographed