Construction and Evaluation of a Scale Model of The Chalmers Formula Student Car

Sammanfattning

In Formula Student competitions, small improvements in aerodynamic performancecan have a decisive impact on overall vehicle competitiveness. The aim of thisproject was to 3D-print a modular scale model of the Chalmers Formula Studentcar, enabling aerodynamic evaluation of a few design configurations in both computationaland experimental environments.The original vehicle geometry was simplified in CAD to simplify manufacturingand ensure feasibility of scale-model testing. Non-critical features were removedwhile preserving the main aerodynamic surfaces responsible for downforce and draggeneration. The resulting modular model allowed systematic variation of key aerodynamiccomponents across different configurations.Computational fluid dynamics (CFD) simulations were conducted using STARCCM+,where aerodynamic forces and properties were evaluated for each configuration.The same configurations were tested experimentally in the Chalmers windtunnel to enable comparison and validation of the numerical results.The results showed consistent discrepancies between CFD and wind tunnel measurements,with CFD generally predicting higher values of both drag and downforce.Despite these differences in absolute values, the relative trends between configurationswere largely consistent, indicating that CFD could still be used effectively forcomparative design studies.The observed discrepancies are primarily attributed to differences in setup betweenthe numerical and experimental environments, including boundary condition simplifications,surface quality of the printed model, and experimental mounting constraints.Overall, the study demonstrates that although CFD requires careful calibrationagainst experimental data, it remains a valuable tool in the aerodynamicdevelopment of a Formula Student car. Furthermore, the results highlight that smallvariations in surface quality and manufacturing tolerances can have a significant influenceon the resulting aerodynamic performance, underscoring the sensitivity ofscale-model testing.