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My Life in Engineering

A collection of cool projects by Randy Hilston

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2020 Cooper Motorsports FSAE Aerodynamics

For the 2020 FSAE season I further developed my aerodynamics package from my previous 2019 design iteration. Aerodynamic targets were revised after running OptimumL 1D lap time simulations of the 2019 FSAE Michigan Endurance track. All CFD simulations were meshed in Altair Hypermesh and run in Ansys Fluent after tuning the CFD with data from testing. The front wing was modified to increase flow to the undertray and to boost front end downforce. This helps shift the center of pressure forward for reduced understeer at high speeds. A downwash element was added to the nosecone to drive flow lower and produce a tip vortex to manage the front tire wake, allowing for a smaller sidepod inlet and improved downforce in the undertray and rear wing. An array of vortex generators were added to the leading edge of the undertray to improve downforce further. I worked closely with the cooling and exhaust teams to tightly package their systems within the undertray and sidepod to reduce drag. The rear wing efficiency was improved by reducing the flap size compared to the 2019 design and adding endplate cutouts to reduce the size of the tip vortex. General design changes were made to reduce manufacturing time and improve serviceability. For example, all mounting was redesigned with custom quick release fasteners so any component could be removed in under 10 seconds.

Drag Pressure Coefficient 2020.JPG

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