Vehicle aerodynamics and wind tunnel technology are progressing towards more realistic simulations of the real-world on-road environment. This paper presents an overview of the new systems which were implemented during the recent wind tunnel upgrade at Forschungsinstitut für Kraftfahrwesenund Fahrzeugmotoren Stuttgart as well as comparable computational fluid dynamics simulations. The fully interchangeable road simulation system features an interchangeable five-belt system and three-belt system in the same full-scale automotive wind tunnel. This system offers the efficiency of a five-belt system combined with the more sophisticated ground simulation technique of a wide belt system, which is necessary to assess the aerodynamic properties of sports cars and racing cars. In order to simulate on-road wind conditions, a side-wind generator can be installed to generate a turbulent flow field in the wind tunnel test section. It could be shown that the commonly determined drag coefficient at 0° yaw angle in the smooth flow environment of today’s wind tunnels is not representative of the drag found in real on-road wind conditions. Additionally, the investigations in unsteady side-wind conditions indicate that the commonly used approach to determine the side-wind sensitivity of a vehicle underestimates the forces occurring in turbulent flow conditions. A validated simulation model is presented. The simulation results are in good agreement with the experimental results and can be used as a complementary tool when assessing the unsteady aerodynamic behaviour of a vehicle; this behaviour can be coupled to a vehicle dynamics model for virtual road testing in the Stuttgart full-motion driving simulator. The unsteady-behaviour effects can be evaluated comprehensively, and the results allow a subjective assessment of the unsteady response of the vehicle. Furthermore, the aeroacoustic wind noise in on-road wind conditions is investigated during the development of the vehicle. The side-wind generator reproduces the natural stochastic cross-wind and allows the effect of these wind conditions to be investigated in the aeroacoustic wind tunnel. The results show similar ratings to those in on-road tests when compared with subjective listening tests. In summary, the techniques introduced open up new horizons in the field of vehicle aerodynamics and aeroacoustics, which are a step closer towards real-world conditions in automotive engineering.

<div class="section abstract"><div class="htmlview paragraph">Natural wind, roadside obstacles, terrain roughness, and traffic influence the incident flow of a vehicle driven on public roads. These transient on-road conditions differ from the idealized statistical steady-state flow environment utilized in CFD simulations and wind tunnel experiments. To understand these transient on-road conditions better, measurements were performed on German public highways and on a test site. A compact car was equipped with a measurement system that is capable of determining the transient airflow around the vehicle and the vehicle’s actual driving state. This vehicle was driven several times on a predefined 200 km long route to investigate different traffic densities on public highways in southern Germany. During the tests the transient incident flow and pressure distribution on the vehicle surface were measured. With the same test vehicle, individual driving situations were recreated on a test site under weather conditions similar to those of the tests on public roads. This paper presents a comparison of the aerodynamic characteristics measured on public highways and on the test site. Two driving situations were examined at the test site: one is driving the test vehicle without traffic and the other is driving behind a box truck in different distances. This paper compares the realistic properties of the turbulent flow structures and the surface pressure around the vehicle during on-road driving in public traffic with those measured on the testing site. The purpose of this study is to investigate the possibility of reproducing the representative driving on public highways with a simplified approach.</div></div>

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