UCRL-ID-131898 Working Group Meeting on Heavy Vehicle Aerodynamic Drag: Presentations and Summary of Comments and Conclusions Rose McCallen, Walt Rutledge Don McBride, Kambiz Salari Walter Gutierrez, Fred Browand Anthony Leonard, Jim Ross Karlin Roth September 28,199s \ This is an informal report intended primarily forinternal or limited external distribution. The opinions and conclusions stated are those of the author and may or . may not be those of the Laboratory. . Workperformed under the auspices ofthe US. DepartmentofEnergy by the . LawrenceLivermore National Laboratory under Contract W-7405.ENG-48. DISCLAIMER This document was prepared as an account of work sponsored by an agency of the United States Government. 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Available to DOE and DOE contractors from the Office of Scientific and Technical Information P.O. Box 62, Oak Ridge, TN 37831 Prices available from (615) 576-8401, FTS 626-8401 Available to the public from the National Technical Information Service U.S. Department of Commerce 5285 Port Royal Rd., Springfield, VA 22161 Working Group Meeting on Heavy Vehicle Aerodynamic Drag: Presentations and Summary of Comments and Conclusions Jointly written by Lawrence Livermore National Laboratory Sandia National Laboratories University of Southern California California Institute of Technology NASA Ames Research Center Introduction The first Working Group Meeting on Heavy Vehicle Aerodynamic Drag was held at San- dia National Laboratories (SNL) in Albuquerque, New Mexico on August 28, 1998. The purpose of the meeting was to review the proposed Multi-Year Program Plan (MYPP) and provide an update on the Group’s progress. In addition, the technical details of each orga- nization’s activities were presented and discussed. Presentations were given by representatives from the Department of Energy (DOE) Office of Transportation Technology Office of Heavy Vehicle Technology (OHVT), Lawrence Livermore National Laboratory (LLNL), SNL, University of Southern California (USC), California Institute of Technology (Caltech), and NASA Ames Research Center. These presenters are part of a DOE appointed Technical Team assigned to developing the MYPP. The goal of the MYPP is to develop and demonstrate the ability to simulate and analyze aerodynamic flow around heavy truck vehicles using existing and advanced computational tools (A Multi-Year Program Plan for the Aerodynamic Design of Heavy Vehicles, R. McCallen, D. McBride, W. Rutledge, F. Browand, A. Leonard, .I. Ross, UCRL-PROP- 127753 Dr. Rev 2, May 1998). This report contains the technical presentations (viewgraphs) delivered at the Meeting, briefly summarizes the comments and conclusions from the Meeting participants, and out- lines the future action items. The MYPP and Presentations As described in the viewgraph presentations, the project plan is divided into two related and overlapping efforts: Advanced Computations and Experiments of Benchmark Geometries Evaluation of Current and New Technologies Each effort has near-term deliverables as well as longer-term goals. The computations and experiments effort will provide rapid results for simple benchmark geometries, and will then advance to more complex geometries. The evaluation of current and new technolo- gies will continue to provide assessment for promising emerging teclinology. Attached is a list of the presentations delivered at the Meeting (see meeting agenda) and the viewgraphs presented are enclosed herein. Summary Comments and Conclusions MYPP and Budget Past drafts of the MYPP have included a third effort: Demonstration of a Device Integration Process It was hoped that the demonstration of a a device integration process for an existing trailer add-on device would be a near-term effort, with the promise for a long-term impactThis task was omitted from the current draft of the MYPP because of budget constraints. The DOE funding representative, Sid Diamond, has requested that this effort be added back into the MYPP as a task that may be added in the future, if funding permits. It is anticipated that we will receive 80 to 85% of our requested budget for FY99 and FYOO. Our budget estimates are $635K and $l,233K, respectively. This funding is for the computations and experiments and evaluation of new technologies efforts described above and not for the additional demonstration effort. Project Overview For near-term impact the first benchmark case will involve the Sandia integrated tractor- trailer model. Comparisons will be made of Reynolds-Average Navier-Stokes (RANS) and Large-Eddy Simulations, as well as detailed experimental verification. Along with the baseline case of the integrated tractor-trailer, height mismatches and gap distances between the tractor and trailer will be investigated. There are advantages in using the Sandia Model as the first benchmark case. It is a simple geometry with some existing data and some modeling has already been done. Thus, mak- 2 ing it more likely that we will achieve a near-term impact with the existing budget con- straints. In addition, the final results are not proprietary and can be made available for comparison to commercial software (e.g., a results comparison at a workshop). The projected funding needs outlined in the Aero Team’s budget assumed the use of lever- aged funds for FY99 and FYOO. However, more funds will be needed if less than the bud- geted dollars are provided. Possibilities for other funding sources were suggested and action items are outlined below for further investigation of these possible sources. Experiments SNL will provide the results of experiments performed at the Texas A&M wind tunnel for the integrated model at Reynolds number, Re, or 1,600,OOO( Re = UL/v, where IJ and L are characteristic velocity and length scale, respectively, and v is the kinematic viscosity). Time-averaged results are provided from these tests. SNL is providing use of the Sandia Model for the future experiments at NASA Ames, NASA Ames will perform detailed measurements for a range of Re on the Sandia Model in their 7 ft by 10 ft wind tunnel, providing full three-dimensional velocity field and sur- face pressure results. These results are being provided free of charge. Their second series of tests will be run with a donated model from Navistar International for a Re sensitivity study. These tests will be performed in the NASA Ames 12 foot wind tunnel at a range of Re up to 5,000,OOO.T he 12 ft tunnel test will be accomplished at one-third cost. USC will perform experiments at two Re within the range of 200,000 to 400,000 using the Sandia Model, with and without trailer-tractor height mismatch and gaps. Tunnel instm- mentation will be provided using leveraged funds. Computations SNL will perform the RANS calculations for high and low Re cases of the Sandia Model. The LES for low Re with some attempt at high Re will be performed by LLNL using a finite element method and by Caltech using a vortex method approach. Future Meetings and Workshops It was suggested that the location of the Working Group Meetings rotate among the Aero Team’s facilities. The next Working Group Meeting will be held at NASA Ames during the scheduled Sandia Model testing, which should occur in the December 1998 to Febru- ary 1999 time frame. LLNL will assist NASA in the meeting planning. DOE sponsors requested that the next Aero Drag Workshop be held in the Fall of 1999. LLNL will be responsible for the Workshop, but the entire Aero Team and DOE sponsors will be directly involved in the Workshop planning and organization. Action Items The follow-on prioritized action items with the individuals responsible for the tasks are as 3 follows: 1. Distribute viewgraphs and meeting results. (R. McCallen) 2. Develop a combined project plan with milestones clearly showing the contribution of each organization and how all the contributions come together. (R. McCaIlen) 3. Schedule site visits to Paccar, Mack, and Schneider. (R. McCallen) 4. Start planning work shop for Fall 1999. Investigate the possibility of connecting it with and existing conference (e.g., Truck Maintenance Council meeting in October 1999, see SAE web page). (R. McCallen) 5. Plan next working group meeting at NASA Ames around January 1999. (J. Ross and K. Roth) 6. Add back into MYPP the Section on demonstration of a device integration process and distribute the MYPP for feedback first from Aero Team and DOE sponsors and them from industry and others. (R. McCallen) 7. Investigate California State funding sources. (F. Tokarz and E Browand) 8. Draft letter of appreciation to Navistar International for their exceptional participation in our effort. (R. McCallen) 9. Publish results at SAE conferences (e.g., Technical Meetings in February). (All Aero Team members) 10. Investigate rumors of new Volvo integrated tractor trailer. (R. Wares) 11. Provide Aero Team with GTRI’s project plan for preliminary review. (S. Diamond) 12. Investigate the possibilities of ‘collaborators’ (i.e., industry, universities, and laboratories). (J. Routbort) 4 - Agenda - Truck Aero Team Meeting Sandia National Laboratories, Albuquerque, NM August 28,199s Purpose of Meeting Review of plans Update on progress Technical details of approach and results Introduction Introduction to Sandia National Laboratories (Walt Rutledge) Project and Budget Update (Sid Diamond) Overview of Project Plan and Budget (Rose McCallen) Experimental Work and Progress Existing Data from Texas A&M (Walt Gutierrez) Wind Tunnel Tests at USC (Fred Browand) Work on New Model Designs (Fred Browand) NASA 7.~10’ and 12’ Wind Tunnel Tests (Karlin Roth) Computational Work and Progress RANS and LES Modeling Plans and Results at SNL (Kambiz Salari) FEM and LES Development and Modeling Plans at LLNL (Rose McCallen) Vortex Method and LES Development and Modeling Plans at Caltech (Tony Leonard) Evaluation of New Technologies Wrap-up Discussion Calendar of Near Term Events (e.g., Site Visits, Next Progress Meeting, Experiments) Near Term Action Items r AERODYNAMICS DRAG MEETING SANDIA NATIONAL LABORATORIES FRIDAY, AUGUST Z&l998 Attendance List Attendee Organization Contact Addresses Sid Diamond DOE/OTT/OHVT Tel: (202)586-8032 FAX: (202)586-1600 e-mail: [email protected] Frank Tokarz LLNL Tel: (925)423-3459 FAX: (925)423-7914 e-mail: tokarzl @llnl.gov Kambiz Salari SNL Tel: (505)844-9836 FAX: (505)844-4523 e-mail: [email protected] Walt Gutierrez SNL Tel: (505)844-5975 FAX: (505)844-4523 e-mail: [email protected] Tony Leonard Caltech Tel: (606)395-4465 FAX: (606)449-2677 e-mail: [email protected] Karlin Roth NASA Ames Tel: (650)604-6678 FAX: (650)604-2238 e-mail: [email protected] Rose McCallen LLNL Tel: (925)423-0958 FAX: (925)422-3389 e-mail: mccallenl @llnl.gov Richard Wares DOE/HVST Tel: (202)586-803 1 FAX: (202)586-1600 e-mail: [email protected] Fred Browand USC Tel: (213)740-5359 FAX: (213)740-7774 e-mail: [email protected] Walt Rutledge SNL Tel: (505)844-6548 FAX: (505)844-4523 e-mail: [email protected] Jules Routbort Argonne Nat. Lab. Tel: (630)252-5065 FAX: (630)252-3604 e-mail: [email protected] I r The truck industry relies on wind tunnel and field experiments for aerodynamic design and analysis. Wind Tunnel Testing Costly detailed models $2,000 to $4,00Olhr Trial-error approach to determine the drag effects due to - general tractor shape, under-body and underhood flow - positioning and shaping of head lamps or turning lights - mirror and grab handle configurations and positioning - tractor-trailer gaps and height mismatch Field Testing Performed by both manufacturer and fleet operators Conventional Issues A tractor is paired with several different trailers Almost no aero design interaction between tractor and trailer manufacturers The effects of design changes on drag are not well understood and computational guidance is needed and welcomed