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ANALYSIS OF DEVICES USED IN AERODYNAMIC TESTING
Ergashev Dostonbek Pratovich
Assistant, Andijan State Technical Institute
Abstract:
Aerodynamic testing plays a critical role in modern automotive engineering, enabling
accurate analysis of vehicle airflow behavior and drag coefficients. To simulate real-world
conditions and validate computational models, specialized devices are employed in wind tunnels
and laboratory environments. This study examines the key components involved in aerodynamic
testing, including scaled car models, wind tunnels, smoke generators, force measurement
systems, and digital sensors. The objective is to analyze the efficiency, accuracy, and integration
of these devices in experimental procedures. Through this analysis, the study provides insights
into optimizing testing methodologies to achieve better precision in aerodynamic design and
development.
Keywords:
Aerodynamics, wind tunnel, drag force, smoke generator, force sensor, scaled model,
automotive testing
1. Introduction
The pursuit of fuel efficiency, high performance, and environmental sustainability has directed
automotive research toward optimizing aerodynamics. Aerodynamic testing, as a vital aspect of
vehicle development, provides engineers with data to evaluate airflow, drag, lift, and other forces
acting on a vehicle in motion. While computational fluid dynamics (CFD) offers theoretical
insights, physical experiments remain indispensable for validation.
In Uzbekistan and other developing automotive markets, interest in establishing experimental
aerodynamic laboratories has increased. This research focuses on analyzing the function and
construction of experimental devices used in aerodynamic testing, particularly in the context of
scaled car models in wind tunnel environments. The goal is to enhance accuracy and reduce
design iteration costs during vehicle development.
2. Methods
2.1. Overview of the Experimental SetupThe experimental system for aerodynamic testing
typically consists of:
A closed or open-circuit wind tunnel.
Scaled-down automobile models (1:10 or 1:5 scale).
A smoke generator and laser sheet for visualizing airflow.
Force-measuring platform with multi-axis load cells.
High-speed camera or sensor array for data collection.
2.2. Construction of the Wind TunnelThe wind tunnel used in this study was a subsonic, open-
circuit tunnel constructed from durable acrylic and aluminum profiles. A centrifugal fan powered
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by a 2.2 kW electric motor generated controlled airflow. The test section measured 300 mm x
300 mm x 700 mm, with a honeycomb mesh to ensure laminar flow.
2.3. Smoke Visualization and Flow AnalysisTo analyze airflow over the car model, a smoke
generator with glycol-based fluid was utilized. A laser sheet illuminated the flow, and a high-
speed camera recorded the behavior of smoke lines. This helped in identifying flow separation,
vortices, and laminar-to-turbulent transitions.
Figure 1. Schematic of a closed-circuit wind tunnel with an open test section. 1 – adjustable
blades, 2 – return channel, 3 – turning vanes, 4 – settling chamber, 5 – nozzle, 6 – test section, 7
– annular diffuser, 8 – diffuser, 9 – fan, 10 – transition section, 11 – fan group supports, 12 –
electric motor
2.4. Scaled Model and Mounting SystemA 1:10 scale model of a compact vehicle was produced
using 3D printing technology. It was mounted on a low-friction platform connected to a load cell
system that recorded drag and lift forces. The model included interchangeable components
(spoilers, diffusers, etc.) to study their effects on drag.
2.5. Data Acquisition and SensorsThe force measuring system used digital strain gauge sensors
connected to a microcontroller with real-time data logging. Calibration was performed using
known weights. Airspeed was measured with a hot-wire anemometer, and temperature and
pressure were logged to account for air density variations.
3. Results
3.1. Drag Force MeasurementThe system successfully measured drag forces within a ±3%
accuracy range. The baseline drag coefficient (Cd) for the scaled model was calculated to be 0.36,
closely matching computational predictions.
3.2. Effectiveness of Flow VisualizationSmoke streamlines clearly revealed turbulent wake
regions behind the model and flow separation over curved surfaces. Addition of aerodynamic
elements such as a rear spoiler reduced wake turbulence and slightly lowered drag.
3.3. Sensor Response and Data PrecisionForce sensors demonstrated high stability and
repeatability. Data acquisition intervals of 0.1 seconds allowed detailed dynamic analysis of
force fluctuations.
3.4. Limitations ObservedSome challenges included smoke diffusion in high-speed flow, minor
model vibrations, and the need for precise alignment of the model within the test section. These
were partially mitigated by structural reinforcements and flow straighteners.
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Figure 2. Pressure distribution in the wind tunnel circuit. a – static pressure, b – total pressure, 1
– transition section, 2 – turning vane, 3 – return channel, 4 – settling chamber with honeycomb, 5
– nozzle, 6 – test section with model, 7 – diffuser
4. Discussion
The experimental analysis confirms that cost-effective aerodynamic test setups can yield
valuable data for vehicle design improvements. The use of scaled models, when constructed and
calibrated properly, enables close approximation of full-scale behavior. Integrating smoke
visualization techniques allows intuitive interpretation of complex airflow patterns, which is
essential for engineering decision-making.
Force sensors and data loggers proved effective for quantitative evaluation, although their
precision depends on structural stability and environmental conditions. The modular design of
the testing platform permits the study of various aerodynamic modifications efficiently.
Comparison with CFD results revealed a strong correlation, reinforcing the validity of the
experimental approach. Further improvements could involve using wind tunnels with automated
velocity control and integrating AI-based flow analysis tools.
5. Conclusion
This study highlights the feasibility and effectiveness of using scaled-down aerodynamic testing
setups in academic and industrial research. The integration of smoke visualization, precise sensor
technology, and modular vehicle models provides a robust platform for analyzing aerodynamic
forces and flow behavior. These devices, when combined, contribute significantly to reducing
the time and cost of vehicle aerodynamic optimization. Expanding such testing facilities in
Uzbekistan’s technical universities could foster innovation in vehicle design and support the
domestic automotive industry.
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