E-MOBILITY
The
advantages of composite materials are being increasingly leveraged to enhance aerodynamics
AI generated vehicle engineering Due to the efficiency of EV motors
and regenerative braking, aerodynamic performance becomes a more significant factor than mass in EVs, if range is the primary consideration. Based on Contechs’ internal vehicle simulations for an EV SUV, a reduction of 0.1Cd (a measurement of aerodynamic drag) resulted in the same range improvement as a mass reduction of 560kg. “Boat tailing, wheel and braking
geometry, panel sealing and powertrain cooling are all key areas where aerodynamic drag can be reduced,” Trueman says. “We can engineer really small, thin structural areas to bleed pressure and control vortices, design alternative load paths and closed wheels to support aerodynamic optimisation in the early phases that can make huge differences and increase range.”
INTEGRATING COMPOSITES The advantages of composite materials are being increasingly leveraged to enhance aerodynamics through thin structures, deep draw geometry and optimised stiffness. “Composites can be used for a
lot more than just saving weight,” Trueman offers. “Because they have a fundamentally different structure, you can get composites to do things that your traditional metals and polymers can’t, while being a lot stiffer. However, it’s about understanding the right place and application on the vehicle to use composites, and where they can be used in combination with materials like
advanced aluminium alloys and high- strength steels to make big differences. These applications might not always be the ‘sexy’ things everyone likes to shout about – take a wing mirror for instance – but these are often the areas that make the big difference.”
SPEED TO MARKET WITH SIMULATION Compressed OEM timing plans mean speed to market is crucial, however traditional methods in body and chassis design and manufacture involve long lead-time CAE simulation and physical prototypes. To bypass this challenge, Contechs is researching and deploying topology simulations and deep generative models driven by Large Language Models (LLM) that allow body and chassis engineers to generate over 100 iterations per minute. “These technologies allow us and our customers to work through design
CFD simulation of electric vehicles
changes much quicker and reduce the back-and-forth of numerous iterations and changes,” Trueman says. “All of these prediction tools allow greater visibility so you can make more informed design decisions earlier on in the process.” Contechs foresees machine learning
algorithms will play a pivotal role in optimising EV designs, and is now working towards implementing these technologies on future projects. These algorithms can analyse vast datasets to consider factors such as material properties, package, crash, and structural performance, and identify patterns and correlations within previous body and chassis data to generate optimised designs. In addition to minimising cost and material usage, this approach could also reduce the number of engineering iterations required to deliver a vehicle programme.
For more information visit:
www.contechs.com
www.engineerlive.com 23
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