UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND ANALYSIS EFFECT OF FRONT AREA OF LAND

ROVER DEFENDER ON AERODYNAMIC

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Engineering Technology

(Department of Mechanical Engineering Technology)(Hons.)

by

AHMAD NAWAWI BIN MOHD AMIN

B071310145

910110105077

FACULTY OF ENGINEERING TECHNOLOGY

2016

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: DESIGN AND ANALYSIS EFFECT OF FRONT AREA OF LAND ROVER DEFENDER ON AERODYNAMIC

SESI PENGAJIAN: 2016/17 Semester 2 Saya AHMAD NAWAWI BIN MOHD AMIN Mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

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9 DISEMBER 2016

Pustakawan Perpustakaan UTeM Universiti Teknikal Malaysia Melaka Hang Tuah Jaya, 76100 Durian Tunggal, Melaka. Tuan/Puan, PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD LAPORAN PROJEK SARJANA MUDA TEKNOLOGI KEJURUTERAAN MEKANIKAL (TECHNOLOGY AUTOMOTIVE): AHMAD NAWAWI BIN MOHD AMIN Suka cita dimaklumkan bahawa Laporan PSM yang tersebut di atas bertajuk

“DESIGN AND ANALYSIS EFFECT OF FRONT AREA OF LAND ROVER

DEFENDER ON AERODYNAMIC” mohon dikelaskan sebagai *SULIT /

TERHAD untuk tempoh LIMA (5) tahun dari tarikh surat ini.

2. Hal ini adalah kerana IANYA MERUPAKAN PROJEK YANG DITAJA OLEH SYARIKAT LUAR DAN HASIL KAJIANNYA ADALAH SULIT. Sekian dimaklumkan.Terima kasih. Yang benar, ________________ Tandatangandan Cop Penyelia * Potong yang tidakberkenaan

NOTA: BORANG INI HANYA DIISI JIKA DIKLASIFIKASIKAN SEBAGAI SULIT DAN TERHAD. JIKA LAPORAN DIKELASKAN SEBAGAI TIDAK TERHAD, MAKA BORANG INI TIDAK PERLU DISERTAKAN DALAM

LAPORAN PSM.

iv

DECLARATION

I hereby, declared this report entitled “Design and Analysis Effect of Front Area of

Land Rover Defender on Aerodynamic” is the results of my own research except as

cited in references.

Signature : ………………………………………….

Author’s Name : AHMAD NAWAWI BIN MOHD AMIN

Date : 1 DISEMBER 2016

v

APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Engineering

Technology (Automotive Technology) (Hons.). The member of the supervisory

is as follow:

………………………………

(DR. ABDUL MUNIR HIDAYAT SYAH LUBIS)

vi

ABSTRACT

The Land Rover Defender was developed from the original Land Rover Series

that in 1983 for the first outcome. There are already 68 years in producing of Land

Rover Defender by the company. The old design for the Land Rover Defender is

considered has no aerodynamic features because related to fuel consumptions. The

design was simple design and not futuristic design to the customers. The

aerodynamics air drag and lift is the main focus for this project report. Thus, the

objective of this study is to do basic study on concept design and analysis of Land

Rover Defender’s front area (front bumper and front hood). This done by sketching

the 1990’s Land Rover Defender and redrawn it on CATIA software before imported

to the HyperMesh for further analysis. Three designs were proposed by modify the

blunt edge of the front bumper and the angle of the front hood. The designs then

imported to the Virtual Wind Tunnel (VWT) software for the Computational Fluid

Dynamics (CFD) analysis to determine the effect of the design on the drag (CD) and

lift (CL) coefficient for the stability for the car. The value of the drag coefficient, CD,

results in this analysis is 0.639 (Original Design), 0.598 (Custom Design 1), 0.566

(Custom Design 2) and 0.612 (Custom Design 3) while for the lift coefficient, CL

results is -0.234 (Original Design), -0.126 (Custom Design 1), -0.216 (Custom

Design 2) and -0.137 (Custom Design 3). Increasing the angle of front bumper and

front hood affected the result of CD which provide more air flow area, thus the air

flow will disperse to reduce CD. For the lift coefficient, by increasing the angle of

front bumper and front hood affected the result of CL is negative, which means to

keep the vehicle nearer to the ground and makes the vehicle more stable.

vii

ABSTRAK

Land Rover Defender telah dibangunkan dari asal Land Rover Siri yang pada

tahun 1983 untuk hasil yang pertama. Sudah 68 tahun dalam menghasilkan Land

Rover Defender oleh syarikat. Reka bentuk lama bagi Land Rover Defender

dianggap tidak mempunyai ciri-ciri aerodinamik kerana ia sangat berkaitan dengan

penggunaan bahan api. Reka bentuk ini adalah reka bentuk mudah dan reka bentuk

tidak futuristik kepada pelanggan. Seretan aerodinamik udara dan lif merupakan

fokus utama untuk laporan projek ini. Oleh itu, objektif kajian ini adalah untuk

melakukan kajian asas kepada reka bentuk konsep dan analisis kawasan hadapan

Land Rover Defender (bumper depan dan hud hadapan). Ini dilakukan dengan

melakarkan tahun 1990-an Land Rover Defender dan dilukis semula pada perisian

CATIA sebelum diimport ke HyperMesh untuk analisis selanjutnya. Tiga reka

bentuk telah dicadangkan kemudian diimport ke perisian Virtual Wind Tunnel

(VWT) bagi pengiraan dinamik bendalir (CFD) analisis untuk menentukan kesan

reka bentuk pada seretan (CD) dan lif pekali (CL) untuk kestabilan untuk kereta. Nilai

pekali seretan, CD, keputusan dalam analisis ini adalah 0,639 (Design Original),

0,598 (Custom Design 1), 0,566 (Custom Design 2) dan 0,612 (Custom Design 3)

manakala bagi pekali daya angkat, keputusan CL adalah - 0,234 (Design Original), -

0,126 (Custom Design 1), -0,216 (Custom Design 2) dan -0,137 (Custom Design 3).

Meningkatkan sudut bumper depan dan hud hadapan membuat hasil daripada CD

yang lebih pendedahan kepada udara yang masuk, dengan itu aliran udara akan

mendapatkan rintangan lebih pekali seretan. Untuk pekali daya angkat, dengan

meningkatkan sudut bumper depan dan hud hadapan menjadikan hasil daripada CL

adalah negatif, yang bermakna ia menolak kenderaan lebih dekat ke tanah dan

membuat kenderaan menjadi lebih stabil.

viii

DEDICATION

This project and research work is dedicated to my beloved parents for their

enthusiastic caring throughout my life, my loving siblings, my supervisor/co.

supervisor and also my friends for their encouragement and love

ix

ACKNOWLEDGEMENT

For my acknowledgement, I would like to express my gratitude and thanks to

ALLAH S.W.T for the blessings given to finish up my thesis.

I dedicate my dissertation work to my family and all my friends. To my

parents, Mr. Mohd Amin Bin Zakaria and Mrs. Mas’Aidah Binti Muknadi, you are

my inspiration and strong. Thank you for your supported and believing in me and

always prays for me. Family is always being there when I was in trouble during

conducting this research.

An enormous gratitude to my supervisor Dr Abdul Munir Hidayat Syah Lubis

for all the guidance given to me finishes this research. The supervision and support

that he gave truly help the progression and smoothness of completing this project.

Also not forget to my co. supervisor Mr. Mohd Idain Fahmy Bin Rosley. All this is

one of the success-key for my research.

Thanks also to Pinz Rover Garage (RPG), Mr. Rosli and Mr. Yahaya for

allowing me to use a 1990’s Land Rover Defender in dimensioning and get

information about the car. A lot of thanks also to Mr. Mohd Suffian Ab Razak, Mr.

Mohd Faruq Abdul Latif and Mr. Saiful Naim Sulaiman for teaching me in using

software Hypermesh and also to the entire teaching engineers and lab assistants who

helped me a lot. To the panel Mr. Aludin Mohd Serah and Mr. Mohd Farid Ismail,

thanks also goes for being a wise and prudent panel to provide scoring.

Not to forget, special thanks for all of my friends that always supported me

throughout the process in finishing this thesis. All of encouragement will always in

my mind in order to keep moving forward. Thanks to all.

x

TABLE OF CONTENT

Declaration iv

Approval v

Abstract vi

Abstrak vii

Dedication viii

Acknowledgement ix

Table of Content x

List of Tables xiii

List of Figure xiv

List Abbreviations, Symbols and Nomenclatures xvi

CHAPTER 1: INTRODUCTION 1

1.0 Introduction 1

1.1 Problem statement 2

1.2 Objective 3

1.3 Scope of study 3

CHAPTER 2: LITERATURE REVIEW 4

2.0 Introduction 4

2.1 History of Land Rover Defender 4

2.1.1 Front design 5

2.1.2 Function of parts 9

2.2 Aerodynamics analysis 10

2.2.1 Aerodynamics 10

2.2.2 Scope of automobile aerodynamics 11

2.2.3 External flow phenomena of automobile 12

2.2.4 Factors contributing to flow field around vehicle 13

2.2.5 Force and moment on vehicle 15

xi

2.3 CATIA (Computer Aided Three Dimensional Interactive Application) 18

2.3.1 Scope of application 18

2.4 Hypermesh 19

2.4.1 Meshing capability 20

2.4.2 Benefit of Hypermesh 22

2.5 Computational analysis (CFD) of car body 23

2.5.1 Outline of computational fluid dynamics process 24

2.5.2 Meshing and pre-processing 24

2.5.3 Numerical solver 25

2.5.4 Post processor 26

2.5.5 Advantages of Computational Fluid Dynamics 27

CHAPTER 3: METHADOLOGY 28

3.0 Introduction 28

3.1 Project step 28

3.2 Conceptual design 29

3.2.1 Sketching 29

3.2.2 Pros and cons of the sketching 29

3.2.3 Finalize idea 30

3.3 CATIA 30

3.4 Simulation 34

3.5 Pre-processing stage for generic model 36

3.5.1 Vehicle generic model and dimension 36

3.5.2 Pre-processing stage for mesh generation 37

3.5.3 Exporting file 43

3.5.4 Virtual Wind Tunnel 44

3.5.5 Optimization 51

3.5.6 Results comparison 51

CHAPTER 4: RESULT AND DISCUSSION 52

4.0 Introduction 52

4.1 Generating correction of model 52

4.2 Meshing 55

xii

4.3 Virtual wind tunnel 58

CHAPTER 5: CONCLUSION AND FUTURE WORK 67

5.0 Conclusion 67

5.1 Suggestion for future works 68

REFERENCES 70

APPENDICES 72

xiii

LIST OF TABLES

Table 3.1: Design and features of the custom design ...............................................30

Table 4.1: Analysis information result .....................................................................60

Table 4.2: Table of results on drag and lift coefficient .............................................63

Table 4.3: Model and wind tunnel geometric...........................................................65

Table 4.4: Mesh statistics ........................................................................................66

xiv

LIST OF FIGURES

Figure 2.1: The first Land Rover Defender, 1983 ..................................................... 6

Figure 2.2: Land Rover Defender, 1990 ................................................................... 6

Figure 2.3: Land Rover Defender body parts, 1990 .................................................. 7

Figure 2.4: New Land Rover Defender plans, 2018 .................................................. 7

Figure 2.5: The 16 models in Land Rover’s future ................................................... 8

Figure 2.6: Front parts of Land Rover Defender ....................................................... 9

Figure 2.7: Streamline of external flows around a stationary vehicle .......................12

Figure 2.8: Sketch views of the various forces and moment on vehicle body .…..... 15

Figure 2.9: HypeMesh on vehicle aerodynamic…………………………………….23

Figure 3.1: Project flow chart ..................................................................................28

Figure 3.2: Original design of Land Rover Defender ...............................................31

Figure 3.3: Custom Design 1 of Land Rover Defender ............................................32

Figure 3.4: Custom Design 2 of Land Rover Defender ............................................32

Figure 3.5: Custom Design 3 of Land Rover Defender ............................................33

Figure 3.6: CATIA sketching cycle to get the best design on Land Rover Defender 33

Figure 3.7: Wind tunnel model ................................................................................34

Figure 3.8: Process of project simulation .................................................................35

Figure 3.9: Hypermesh 2D meshing ....................................................................... 37

Figure 3.10: Performing auto cleanup .................................................................... 38

Figure 3.11: Finishing of the 2D meshing ...............................................................39

Figure 3.12: Setting on the quality-index panel .......................................................39

Figure 3.13: QI criteria of cleanup tools ................................................................. 40

Figure 3.14: Finishing after clean up tools .............................................................. 41

Figure 3.15: Scaling down the meshing surface .......................................................41

Figure 3.16: Edge and element checking .................................................................42

Figure 3.17: Element and edge checking tab ...........................................................42

Figure 3.18: Deleting solid and surface ...................................................................43

Figure 3.19: Exporting the file ................................................................................43

Figure 3.20: Surface mesh model in Nastran format (.nas) ......................................44

Figure 3.21: The model in Virtual Wind Tunnel ......................................................45

Figure 3.22: Resizing the tunnel dimension ........................................................... 46

Figure 3.23: Model position set up ......................................................................... 47

Figure 3.24: Red color means the model was recognize...........................................48

Figure 3.25: Refinement zone ................................................................................ 48

Figure 3.26: Meshing and physical parameters set up ............................................ 49

Figure 3.27: Virtual wind tunnel analysis .............................................................. 50

Figure 3.28: Result of simulation in pdf format .......................................................50

xv

Figure 4.1: Original design with simply CAD drawing correction ...........................53

Figure 4.2: Custom design 1 with simply CAD drawing correction .........................53

Figure 4.3: Custom design 2 with simply CAD drawing correction .........................53

Figure 4.4: Custom design 3 with simply CAD drawing correction .........................53

Figure 4. 5: (a) Without wheel and (b) With wheel ..................................................54

Figure 4.6: Front grill covered open area .................................................................54

Figure 4.7: Redesign with no eye brow ...................................................................55

Figure 4.8: Original design meshing result ..............................................................56

Figure 4.9: Custom design 1 meshing result ............................................................56

Figure 4.10: Custom design 2 meshing result ..........................................................56

Figure 4.11: Custom design 3 meshing result ..........................................................56

Figure 4.12: The mesh in cross section and mesh in flow section without refinement

zones mesh (side view) ...........................................................................................57

Figure 4.13: The mesh in cross section and mesh in flow section without refinement

zones mesh (front view) ..........................................................................................57

Figure 4.14: Velocity Contours of the all car model from side view ........................58

Figure 4.15: Velocity Contours of the all car model from top view..........................59

Figure 4.16: Graph of Drag Coefficient vs. Alteration of each design ......................61

Figure 4.17: Combination graph of Drag Coefficient vs. Alteration .........................62

Figure 4.18: Graph of Lift Coefficient vs. Alteration of each design ........................64

Figure 4.19: Combination graph of Lift Coefficient vs. Alteration ...........................64

Figure 4.20: Position Land Rover Defender car in Virtual Wind Tunnel..................66

xvi

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

FEA - Finite Element Analysis

CFD - Computational Fluid Dynamics

CAD - Computer Aided Design

CD - Drag Coefficient

CL - Lift Coefficient

CATIA - Computer Aided Three Dimensional Interactive Application

1

1.0 Introduction

Land rover was created for heavy road style and specialist in four wheel

drive vehicles. The first owner of the company is British multinational car

manufacturer Jaguar Land Rover. Since 2008, the company turn owned by

India’s Tata Motors. The name of Land Rover was originally used by the Rover

Company for the Land Rover series that launch in 1948. The first prototype was

built by the company was designed for the army. This iconic car was improved

over the years and it has been known for generations as a national treasure. All

models is based on four wheel drive models, including Defender, Range Rover,

Discovery, Freelander, Range Rover Sport and Range Rover Evouge.

Production of the model Defender began in 1983 as the Land Rover One

Ten, 1983, a name which reflected the 110-inch (2,800 mm) length of the

wheelbase. The Land Rover Ninety, 1984, with 93-inch (2,362 mm) wheelbase,

and Land Rover 127, with 127-inch (3,226 mm) wheelbase, soon followed as

now (liquisearch, 2016).

Aerodynamics plays an important thing in the development process

nowadays. Aerodynamics loads is influenced for the vehicle performance, its

stability and the vehicle cooling system. Its also for the drivers comfortable and

visibility. From that side, the automotive industries nowadays applied wind

tunnel experiments and Computational Fluid Dynamic (CFD) simulations to

study the aerodynamic loads on their vehicles.

INTRODUCTION

CHAPTER 1

2

Aerodynamic drag is the force that acts on a body moving through air that

opposite to the direction of motion of the vehicle. It may cause and affects the

performance and fuel efficiency. Total fuel energy is lost around 50% to 60% to

overcome the drag force, 10% to 20% for operating electrical appliance and 30%

to 40% to overcome road resistance (P Ramaya, 2015). For nowadays, the

aerodynamics drag is one of the prime concerns in vehicle aerodynamics and

great effort in research for better fuel economy and performance road vehicles

due to market competition for consumers. It’s also happened in research and

development of the Land Rover Defender.

1.1 Problem statement

With the increasing of automobile industries, people begin to pay

attention to dynamic performance of automobile including the Land Rover

industry. Front area in all cars, including the front bonnet, front grill, both sides

of front eyebrows, is the most important to the aerodynamics features to reduce

the air drag. The old Land Rover Defender design is just a simple design that the

shape is consider did not possess aerodynamics design features.

Aerodynamics are affected the driving safety, operations, characteristics,

stability and oil consumption of the vehicle. Therefore, redesigning the front area

of the Land Rover Defender as to look more aerodynamically and look more

futuristic, light in their weight and also reduce number of components or panels

for the aerodynamics design features are required.

Since lack of information on 1990’s Land Rover Defender aerodynamic

air drag was not much found, study about this is considered important. This

factor because of the company made the information of the design as Private and

Confidential. That’s why; this project subjected to the aerodynamic drag for the

1990’s Land Rover Defender with the design provided in this research.

3

1.2 Objective

The objectives of this project are:

1. To do basic study on concept design front bumper and front hood of

1990’s Land Rover Defender.

2. To determine effect of designed front part to drag coefficient (CD) of the

1990’s Land Rover Defender.

3. To determine effect of designed front part to lift coefficient (CL) of the

1990’s Land Rover Defender.

1.3 Scope of study

The scopes of study of this project are:

1. Sketching and feature modelling of 1990’s Land Rover Defender by using

CATIA.

2. Focusing on the effect drag and lift coefficient on the shape of Land

Rover Defender 1990’s based on aerodynamic features.

3. Computational fluid dynamics analysis by using HyperMesh processor

software.

4

2.0 Introduction

This chapter will be focused on the information of the research and the

results of the study about the design and analysis front area (both sides and front

hood) of Land Rover Defender in terms of the shapes and materials. This

knowledge then will be used as the guideline to find the most suitable design

based on the factor and the supported theory to finalize the design based on the

scopes of the project.

2.1 History of Land Rover Defender

The Land Rover Defender was created from the first Land Rover Series

that in 1983 for the main production. There are also called as Land Rover Ninety

and Land Rover One Ten. Until now, the Land Rover Defender has many sorts

and models that distinctive design and usefulness. There are as of now 68 years

in delivering of Land Rover Defender by the organization. Creating of the Land

Rover One Ten at 1983 and Land Rover Ninety at 1984 is the base of the

organization for the generation and that is the reason the Land Rover Defender

was called as the name of Land Rover Ninety and Land Rover One Ten.

Indeed, there is little to recognize the post-1983 vehicles from the Series

III Land Rover. A full-length cap, reconsidered grille, in addition to the fitting of

LITERATURE REVIEW

CHAPTER 2

5

wheel curve expansions to cover more extensive track axles are the most

perceptible changes. At first the Land Rover was likewise accessible with low

maintenance 4WD system well known to all subsidiaries created since 1949,

showing Land Rover's anxiety for innovative advancement. The low maintenance

framework neglected to offer and was immediately dropped from the choices list

by 1984. While the motor and other body boards extended from the Series III,

mechanically the Ninety and One Ten was modernized, including on the curl

springs, offering a more agreeable ride and enhanced pivot enunciation. A

changeless four-wheel-drive framework got from the Range Rover, including a

two-speed exchange gearbox with a lockable focus differential. Likewise

changes of the inside for look present day, a taller one-piece windscreen and

another arrangement of logically more effective and more cutting edge motors

(historics.co.uk, 2015).

After 68 years of the Land Rover Defender creation, October 2013 Land

Rover reported that the generation would be end in December 2015 lastly

finished on 29 January 2016 with the model Land Rover Defender H166 HUE.

2.1.1 Front design

The Land Rover Defender car’s first body design is was in 1983

and 1984 is the base of the company for the production and that’s why the

Land Rover Defender was called as the name of Land Rover Ninety and

Land Rover One Ten. However, there are revolutions on their design

every series outcomes based the years of the productions. The design is

for the military used for the army. All design is for the off road and tough

job. Therefore, the all materials used are hard and tough based on metals

and aluminium.

6

Figure 2.1: The first Land Rover Defender, 1983 (beachautobrokers, 2016)

In a 1983, 'Birmabright' is the materials that used by the designer

of the Land Rover Defender for the production of the car. However, in

their manufactured, there is some difficulty facing especially for the parts

used in and for the spare parts while change the materials. The parts are

assembling by riveting to other parts. The design also not too

aerodynamics features.

Figure 2.2: Land Rover Defender, 1990 (landrover, 2016)

7

Figure 2.3: Land Rover Defender body parts, 1990 (globallandrovers, 2016)

At 1990 the Land Rover Defender changed their front design from

the previous to look more advance in aerodynamics. The materials used in

the production of the Land Rover Defender in that year are aluminium

plate as the main materials for the body.

Figure 2.4: New Land Rover Defender plans, 2018 (autoexpress, 2015)

8

The Land Rover Defender will come out with the new design and

version in 2018 with SVR execution form on the cards to rival the Merc

G63 AMG. This new design is more modern, futuristic, sports and more

streamlined features highlights or aerodynamics. The front body parts are

basic than past design and utilized more lightly, hard and suitable

materials (autoexpress, 2015).

Figure 2.5: The 16 models in Land Rover’s future (mailonline, 2012)