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Car Body Design and Aerodynamics Notes
Politecnico di Torino automotive engineering (ingegneria dell'autoveicolo) Curriculum vehicle system development 2025
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- Car Body Design - Packaging & Ergonomics:
- Focuses on optimizing interior space for safety, comfort, and control accessibility.
- Utilizes anthropometry (statistical body measurements, percentiles) to model drivers.
- Emphasizes proper backbone posture and uses manikin models (SAE J826) for seating and eye ellipses (SAE J1052) for visibility.
- Outlines pedal configurations, considering heel point (HP) and H-point.
- Structural Configuration:
- Compares body-on-frame (modularity, NVH isolation) and unibody (lighter, lower CG, integrated structure) designs.
- Identifies key structural members: longitudinal beams, cross beams, sills, and pillars (A, B, C).
- Discusses cross-section designs for stiffness and to prevent rust.
- Explores suspension load distribution and the role of cross members.
- Structural Analysis:
- Applies Bredt equations for calculating torsional stiffness in thin-walled, closed cross-sections.
- Examines global (bending) and local (folding) instability for energy absorption.
- Illustrates plastic deformation types: concertina (extensional) and diamond (inextensional) modes.
- Discusses the use of structural foams for energy absorption.
- Pedestrian Impact:
- Defines critical impact zones (leg, hip, head) and uses specialized impactors for testing.
- Outlines legislative test procedures for impact speed, angle, and critical points.
- Engine Suspension (NVH - Noise, Vibration, Harshness):
- Ensures torque transmission, engine support, and vibration attenuation.
- Explores different mount types: rubber (viscoelastic, non-linear), hydraulic (variable damping), and magnetorheologic (magnetic field-controlled viscosity).
- Details mount configurations (3 mounts, CG alignment, single rod) for optimal performance.
- Analyzes dynamic excitations from road, wheels, and powertrain using Power Spectrum Density (PSD).
- Aerodynamics Principles & Characteristics:
- Covers Bernoulli's principle (faster flow = lower pressure), Coandă effect (flow attachment), and Magnus effect (spinning object creates force).
- Defines flow characteristics: density, viscosity, Reynolds and Mach numbers.
- Explains boundary layer phenomena: laminar vs. turbulent flow, and boundary layer separation (leading to drag).
- Classifies bodies as aerodynamic or bluff, relating shape to dominant drag type.
- Computational Fluid Dynamics (CFD):
- Utilizes Navier-Stokes equations for mass, momentum, and energy conservation.
- Details the CFD process from CAD to meshing, solver execution, and post-processing.
- Addresses mesh quality factors (skewness, smoothness, aspect ratio) and turbulence modeling (DNS, LES, RANS).
- Aerodynamic Applications:
- Focuses on drag reduction strategies for the front profile, windscreen, A-pillar, rear end, and underbody.
- Discusses air dams, rockers, rear-view mirrors, and spoilers for managing airflow.
- Explores the aerodynamic impact of wheels and wheelhouses.
- Addresses cooling drag, active grille shutters, and the comprehensive design of vehicle underbodies.
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