Aerodynamic Drag Reduction in Commercial Vehicle Using CFD-Based Design Optimisation

Background The aerodynamics of commercial vehicles is complex. The bluff body of a truck creates complex airflow patterns and induces drag. Numerous researchers have concentrated on enhancing the design of passenger cars, whereas the aerodynamic design of trucks has been largely overlooked. Truck operators are often unaware of the drag force acting on the truck and its impact on annual fuel consumption. Trucks can save large amounts of fuel annually by improving their aerodynamics. Most trucks are currently operating on the road without any frontal wind deflector, which causes drag accumulation over the frontal region of the truck. Method This study aims to reduce the drag force of an SCV through effective design optimization using the ANSYS Fluent tool. Using CFD methods and various numerical techniques, a comprehensive 3D airflow analysis was conducted on a scaled-down truck model. Subsequently, design optimizations were performed on the baseline truck to enhance its aerodynamic efficiency. A systematic literature review was conducted to obtain insights into the flow field of commercial vehicle drag-reduction techniques. Results Flow analysis was performed using different turbulence models, and the results were validated using available literature data. To improve the aerodynamic performance of the truck, different geometrical optimization models were tested on an iterative basis. Each model was further compared with the baseline model to obtain more reliable results. An airflow analysis was conducted for different air velocities. The obtained drag values for both the aerodynamically optimized truck and the baseline truck were compared and analyzed. Effective design alterations led to an 18% reduction in drag. Conclusions The enhanced aerodynamic outcomes are presented in detail for the optimized truck model. This study will help automobile engineers and truck researchers to understand the flow aerodynamics of commercial vehicles and improve their aerodynamic efficiency.