The recent volatility of fuel prices and the potential of explicit CO2 emission control regulations have caused aerodynamic performance to become a critical component of heavy vehicle development. The use of traditional computational fluid dynamics (CFD) simulation for aerodynamic drag prediction on fully complex production geometries has not been adopted for a number of key reasons: the high level of expertise required, simulation time-to-completion, and accuracy versus experiment. This paper demonstrates that the proprietary, Lattice-Boltzmann based simulation method of EXA Corporation delivers valuable results on fully complex geometry, allowing aerodynamic optimization in the concept and design phase. Included is an overview of the simulation method and results for two fully detailed open grille Kenworth models: the T603 and T2000. Comparisons are made to full scale drag meter testing. Additional results are provided for several trailer drag reduction devices including a full gap seal, side skirts, boat tail, and wake boards. Advanced post-processing of the simulation results is used to study transient flow structures and highlight the physics involved with the drag reduction of these devices.


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