← All projects

Rowan University / Fluid Mechanics final project / 2024

Aerodynamic Car Design.

More downforce.
A better aerodynamic tradeoff.

A team-designed SolidWorks car built around one objective: maximize downforce relative to drag while working within the course’s physical and dimensional constraints.

Blue CAD model of the car showing the shaped body, rear wing, and vortex generators
The final car model · integrated body and aerodynamic features
Team
James Lee · Nicholas Stephan · Blake Viggiano
Benchmark speed
150 mph
Reported downforce
1,998 lbf
Downforce / drag
2.80 at the benchmark

Watch the project

Hear the team explain the design.

Team presentation · James Lee, Nicholas Stephan & Blake Viggiano

Fluid Mechanics Aero Project

Our recorded project presentation accompanies the slides and gives another way to explore the car, design choices, and analysis.

Watch on YouTube ↗

01 / The objective

Optimize the relationship between downforce and drag.

A useful aerodynamic design has to consider both the force pressing the car toward the ground and the drag resisting its motion. Our project focused on increasing the magnitude of downforce relative to drag.

We developed the car in SolidWorks and evaluated its aerodynamic forces through flow simulation. The design combined a shaped front body, rear wing, vortex generators, and rear diffuser, rather than treating each feature as a separate add-on.

The team and the surviving record

James Lee, Nicholas Stephan, and Blake Viggiano. This page credits our shared work; the slides do not assign individual responsibilities.

The original assignment sheet is no longer available. The presentation retains the dimensioned model views and our reported results, which are used here without reconstructing missing requirements or claiming a class ranking.

A note on the force sign

The executive summary reports lift-to-drag as −2.804045 because the lift force is negative in the model’s coordinate system. For a car, that negative lift is downforce. This page uses the positive magnitude, downforce/drag = 2.804, to make the objective easier to read.

See the original presentation · slide 2 ↗

02 / Model geometry

Shape the airflow within the available envelope.

The dimensioned views document the overall side profile, tire clearance, passenger-compartment width, tire width, overall width, and ground plane.

Slide 4: Overall side profile
Overall side profile · Slide 4 ↗
Slide 5: Tire clearance and side cuts
Tire clearance and side cuts · Slide 5 ↗
Slide 6: Passenger compartment width
Passenger compartment width · Slide 6 ↗

The side cuts preserve space around the tires while changing the surrounding body shape. The front views and ground-plane drawing establish the geometry used for the analysis.

Slide 8: Overall width
Overall width · Slide 8 ↗
Slide 9: Ground-plane dimensions
Ground-plane dimensions · Slide 9 ↗

These are the dimensions visible in the surviving deck. They do not provide the complete original constraint list, so exact compliance limits are not inferred from them.

See the original presentation · slide 4 ↗

03 / Aerodynamic development

Four features, designed to work together.

A gentle front profile

The front body uses a gentle concave slope, with areas beside the passenger compartment cut away. The team’s intent was to reduce front drag and limit unwanted low pressure above the compartment.

Slide 10: Front-profile approach
Front-profile approach · Slide 10 ↗

A rear wing with side panels

The rear wing curves upward to turn the flow and develop downforce. Its side panels were intended to limit lateral escape and help maintain the pressure loading on the wing.

Slide 11: Rear-wing approach
Rear-wing approach · Slide 11 ↗

Vortex generators ahead of the wing

Small features behind the passenger compartment were intended to influence the boundary layer and delay separation before the rear wing. Vortex generators act through local mixing; the slides’ description of increasing “laminar flow” is treated here as a design intention to keep the flow attached, rather than a demonstrated laminar-flow result.

Slide 12: Vortex-generator approach
Vortex-generator approach · Slide 12 ↗

A channeled rear diffuser

The underside uses separate channels and a rear diffuser to shape the underbody flow. The presentation records iterative testing of its length, proportions, and rear-edge treatment, with the final version omitting a rear fillet.

Slide 13: Rear-diffuser approach
Rear-diffuser approach · Slide 13 ↗

The final force results describe the complete model. The deck does not include a separate baseline or a force breakdown for each feature, so it does not establish how much improvement came from any one change.

04 / Simulation results

A benchmark, followed by a speed sweep.

At the 150 mph benchmark, the simulation reported drag of 712.6079 lbf and signed lift of −1,998.1848 lbf. Taking the magnitude of negative lift gives approximately 2.80 units of downforce for each unit of drag.

Slide 2: 150 mph executive summary
150 mph executive summary · Slide 2 ↗
Slide 3: Flow simulation and force components
Flow simulation and force components · Slide 3 ↗

How the ratio changed with speed

Reported downforce-to-drag magnitudes from the speed sweep
Speed (mph)Downforce / drag
502.919
1003.064
1502.804
2002.750
Slide 16: Downforce-to-drag ratio versus speed
Downforce-to-drag ratio versus speed · Slide 16 ↗

The largest ratio among these four reported runs was approximately 3.064 at 100 mph. This identifies the best of the sampled operating points; it does not establish a global optimum or a competition result.

Force rises with speed

Slide 14: Drag force versus speed
Drag force versus speed · Slide 14 ↗
Slide 15: Downforce versus speed
Downforce versus speed · Slide 15 ↗

Both drag and downforce increased across the sweep. The deck reports approximately 3,526 lbf of downforce at 200 mph. More downforce therefore came with increased drag and aerodynamic power demand.

The power cost of drag

Slide 17: Aerodynamic power versus speed
Aerodynamic power versus speed · Slide 17 ↗

The power required to overcome aerodynamic drag follows P = D × V. At 150 mph, the reported drag corresponds to approximately 285 hp of aerodynamic power. This excludes rolling resistance, drivetrain losses, acceleration, and other vehicle loads.

These are modeled forces. The surviving presentation does not provide a mesh-independence study, convergence history, full boundary-condition settings, or measured aerodynamic validation.

See the original presentation · slide 14 ↗

05 / Scaling & supporting calculations

A small model does not automatically reproduce full-scale flow.

The presentation explores a 1/20-scale model in a water tunnel by matching Reynolds number, the ratio of inertial to viscous effects. It uses a full-size reference length of 80 inches and a model length of 4 inches.

Slide 18: Water-tunnel scale-model calculations
Water-tunnel scale-model calculations · Slide 18 ↗

For the stated 150 mph air condition, the slide calculates Reynolds number of approximately 9.08 million. Matching it with the specified water properties requires a water speed of about 89.6 m/s, or 200.4 mph.

That demanding result illustrates a practical limitation of matching Reynolds number at this scale. The slide contains calculations, but does not document a completed water-tunnel experiment or measured forces.

Coefficients and reference area

The same slide calculates downforce-coefficient magnitude of 1.418 and drag coefficient of 0.506 using its stated frontal reference area. Coefficients depend on that area definition; their ratio is consistent with the reported downforce-to-drag magnitude.

A fuel-pump reference

The final slide shows a Holley 130 GPH inline fuel pump as a sizing reference. It does not include the associated fuel-demand calculation, engine assumptions, or installed-system results, so a validated component selection is not claimed here.

Slide 19: Fuel-pump sizing reference
Fuel-pump sizing reference · Slide 19 ↗
See the original presentation · slide 18 ↗

06 / Engineering lessons

Evaluate the whole design—and the evidence behind it.

  • Optimize a tradeoff: greater downforce alone does not guarantee a better downforce-to-drag ratio.
  • Check more than one operating point: the ratio varied across the four speeds even as the force magnitudes increased.
  • Integrate the geometry: the front body, upper surfaces, rear wing, and underbody influence the same flow.
  • Keep simulation settings traceable: mesh, convergence, boundary conditions, and force definitions matter when comparing revisions.
  • Plan a feasible validation method: scale-model similarity requirements can become demanding before any physical test begins.
What the project demonstrates

Collaborative CAD development, an integrated aerodynamic concept, and a structured comparison of modeled force and power across operating conditions. Further work would verify the simulation setup and isolate the effect of individual features.

07 / Full documentation

The presentation, in full.

The complete 19-slide deck preserves the model dimensions, aerodynamic features, force summaries, plots, scale-model calculations, and fuel-pump reference.

Related engineering

More fluid mechanics and aerospace analysis.

← All projects