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Aeroacoustics Simulation of an Automotive A-Pillar Rain
Gutter
Herv Dechipre and Dr. Michael Hartmann Group Research,
Automotive Techniques, CAE Volkswagen AG, Wolfsburg, Germany
SYNOPSIS The recent successes achieved to reduce tire and engine
noise have resulted in a higher contribution of the wind noise in
the overall perception of noise by car passengers. Up to now, wind
noise has been largely assessed by wind tunnel testing; however
there is an increasing need for numerical methods in order to
evaluate the design as early as possible. If direct noise
computation (DNC) is not reachable for industrial applications,
hybrid methods based on acoustical analogy or stochastic modelling
have already demonstrated good aptitudes. Nonetheless, as a first
step, an accurate CFD simulation must be performed. In this study,
the flow-induced noise of an automotive rain gutter has been
investigated for Reynolds numbers based on the rain gutter height
between 20 000 and 130 000. As both rain gutters height and
oncoming flows direction vary along the A-pillar, two
configurations have been designed to investigate these effects
separately. In addition, two different profile sections of rain
gutter were tested. This paper mainly focuses on the computation of
the structures of the flow and surface pressure level; the
propagation of sound in far field will be addressed in a further
publication. The topology of the flow was assessed using steady
RANS computation. Unsteady SAS-SST and DES models have been used to
compute surface pressure fluctuations. As the flow was stable for
the conventional SAS-SST model, forcing terms were used to switch
to unsteady mode. Experimental data will be presented and used to
validate the results of the numerical simulations.
1. Introduction
Various aspects determine the comfort inside a vehicle. One of
them is the interior noise experienced by the passengers. Due to
successes in reducing motor and road/tire noises, airflow induced
noise (also called wind noise) becomes more and more important.
Over 100 km/h wind noise is generally the dominant noise source and
can make it difficult to converse or listen to the radio, but it
can also add fatigue on a long highway trip. A potential buyer
might even consider high wind noise levels as poor design or build
quality and may lead to dissatisfied customers. Therefore, car
manufacturers have to pay close attention to wind noise and try to
minimise it. If one could expect that low drag vehicles would also
have low wind noise level; this is not found to be true in
practice. One explanation for this lack of correlation comes from
the fact that aerodynamic drag depends largely of the airflow over
the rear of the vehicle and its wake
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while interior wind noise depends largely on details of the
exterior airflow around the A-pillar and windscreen. Small openings
or gaps around doors, windows, or many other components on the
outer body such as roof-racks or side-view mirrors (or under floor)
may largely contribute to wind noise; conversely they will have
little or no effect on aerodynamic drag. A prominent feature
contributing to the overall wind noise level in the cabin is the
A-pillar rain gutter (fig. 1). Like a long narrow channel along the
A-pillar, its purpose is to collect and drain the water that would
otherwise flow from the windshield and past the A-pillar along the
side windows; reducing then the visibility.
Fig. 1: Streamlines over a A-pillar
In the last decades, car manufacturers have massively invested
to build aero-acoustic wind tunnel to investigate wind noise,
however to cope with the continual reduction of cost and time
development, there is an increasing need for effective numerical
methods to simulate noise induced by external and internal flows
and which could be systematically used in the early design phase of
a vehicle. Recently, many works have been done to tackle the
simulation of the flow induced noise over side view mirrors [1-2]
and the pressure fluctuations on the cars lateral windows [3-4].
Few works have already addressed the problem of simulating the
noise generated by a simplified rain gutter using a facing elbow
mounted on a flat plate [5-6] or more simply: a forward facing step
[7-9]. However in most of these works, only one geometry and only
constant height of step leading to quasi 2D configurations were
generally considered. Firstly, the different configurations tested
will be presented as well as some experimental results. Methods and
set-up used for the simulations carried out with the commercial
Softwares ANSYS CFX and Fluent will then be presented. Finally, an
overview of the topology of the flow will be addressed and followed
by some comments on the results.
2. Definition of the Test case and Experimental set-up
2.1. Profiles and configurations
Two different rain gutter section profiles were tested, Fig.2.a.
The first profile presents a higher water channel and a sharper
edge. Shown on fig 1 and 2, the rain gutters were mounted on a flat
plate and extended at their back by another plate. On a real
vehicle, the height of the rain gutter is generally not constant
but varies along the A-pillar. Thick at it bases, it becomes
thinner approaching the roof. The streamlines on a car windscreen
(fig.1) illustrates also that the angle of the oncoming flow with
the rain gutter
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varies along the A-pillar. Almost perpendicular (90) at the base
of the A-pillar, the oncoming flow can reach an angle with the rain
gutter of 30 near the roof. In order to evaluate these two
parameters independently, two configurations were designed. Fig.2.b
represents a rain gutter with a height varying linearly from 10 to
42 mm (called Linear). The configuration shown in fig.2.c
(designated as Curved) was designed to study the impact of
different flow angles on the rain gutter. The angle between the
flow and the rain gutter varies from 90 to 35. It then leads to 4
cases (2 profiles 2 configurations).
Fig. 2: Geometry of the rain gutter Configurations
2.2. Experimental Set-up
The 4 cases were tested in the Aeroacoustic wind tunnel in
Braunschweig (AWB) from the German aerospace centre (DLR). The wind
tunnel has an open jet section of 1.20.8 m and the collector has a
section of 3 3 m [10].
Fig. 3: Experimental Set-up for the 2 configurations (Linear and
Curved)
Shown in red on fig 3, the experimental models were equipped of
3 rows of flush-mounted microphones (1/4 and 1/8 inches) to
investigate the effect of the height of the rain gutter and the
direction of the oncoming flow. Five flush-mounted microphones per
row were used in the linear cases. Additional flush-mounted
microphones were placed in the perpendicular direction to the rain
gutter for the curved configuration. The local angles investigated
were 90, 60 and 40. In addition, 10 free field microphones were
used to assess the far field noise. The signals at the microphones
were registered during 22s with a sampling frequency of 45 kHz. The
signal of the far field microphones was corrected using the shear
layer correction of Amiet [11].
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The experimental spectra obtained for the 5 flush-mounted
microphones on the medium section of the linear configuration for
both profiles are presented on fig. 4. The 2 furthest upstream
microphones (Pos. 1 and 2) present for both profiles almost
identical spectra. Only directly in front of rain gutter at
position 3, the measured noise level is about 3 dB higher for the
first profile. The main differences are found behind the rain
gutter. The first profile presents its maximum surface pressure
level (SPL) directly after the rain gutter (Pos. 4) while the noise
level drops down after the second profile. As additional
information, the first profile was measured to be 13 dB noisier
than the second one in the far field (at about ~ 1,8 m).
Fig 4: Experimental narrow band spectra for both profiles at
flow stream velocity of 45 m/s.
3. Numerical Methodology
Steady and unsteady simulations using different models were used
to assess the characteristics of the flow over the different
profiles and configurations. After briefly presenting the models
and methods, a description of the meshes and set-up will be
proposed.
3.1. Turbulence Modelling
The main topology of the flow was assessed by performing steady
Reynolds Averaged Navier-Stokes (RANS) model using the SST k-
turbulence model with the Software ANSYS CFX [12]. In order to get
surface pressure fluctuations, transient computations need to be
performed. The most widely accepted unsteady approach is certainly
the Large Eddy Simulation (LES) where the Navier Stokes equations
are filtered using a spatial operator with a filter-width
proportional to the local space grid spacing. This later aspect
makes a direct connection between the level of resolution of
turbulence scales and the mesh refinement, and can make the method
very expensive for certain complex industrial applications. In
attempt to overcome this restriction, Spalart [13] proposed a
hybrid method which combines features of classical RANS
formulations with elements of the LES methods. This concept called
Detached Eddy Simulation (DES), is intended to take advantage of
both methods by covering the boundary layer by a RANS model and
switching into a LES mode in detached regions. This allows the
calculation to capture the instability of the shear layer, and the
development of the coherent structures in the wake, with more
accurate prediction of the unsteady forces than can be obtained by
steady or unsteady RANS methods. A major drawback of the method is
the explicit grid dependency of the method which can lead to a
premature flow separation. A solution was proposed by Spalart [14]
so called Delayed DES to overcome this problem. The switch for the
DES is achieved by comparing the modelled
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turbulent length scale and the grid spacing and is obtained by
correcting the destruction term as follows:
= k k FDES with FDES = max
1,
DES
t
CL
where Lt is the turbulent length scale predicted by the RANS
model, is the local grid spacing and and CDES are 2 constants.
As an alternative approach, Menter and al. [15] have
investigated the development of an improved URANS method which can
provide a LES-like behaviour in detached flow regions. The scale
adaptive simulation (SAS) concept is based on the introduction of
the von Karman length scale into the turbulent equation and defined
as follow in 1D:
22'' //
yUyU
USLvK
==
where S is the absolute value of the strain-rate and = 0.41.
The information provided by the von Karman length scale allows
the SAS models to dynamically adjust to resolved structures in a
URANS simulation, which results in a LES-like behaviour in unsteady
regions of the flow field. At the same time the model provides
standard RANS capabilities in stable regions. It allows the
development of a turbulent cascade up to the grid resolution into
the detached regions without or small grid dependency.
3.2. Meshing and set-up
The geometry for the different configurations were realised with
Catia V5 before to be imported into ANSYS IcemCFD to be meshed.
Block-structured meshes composed of hexahedral cells were realised.
To get information on the flow topology over both profiles, steady
RANS and unsteady DES computations were firstly performed on a
small part of the rain gutter with constant height. Steady RANS
computations were then realised on the 4 cases. Finally, unsteady
simulations using different turbulence models (SAS-SST, DES and
LES) were carried out on profile 1 with linear configuration.
3.2.1. Comparison between profiles 3D geometries with constant
height
Fig 5: Computational domain and meshes
To get a first understanding of the flow over the two profiles
and the main differences between them, fluid simulations were
performed on an extrusion over 40 mm in the span-
0,55 m
0,15 m
0,04 m
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wise direction for both profiles. The entire meshes consist in 3
400 000 nodes. The resolutions in the span-wise direction are for
the first and second profile 0.5 mm and 0.33 mm respectively to
ensure the coherence of the structure. At the inlet, a free stream
velocity of 45 m/s (162 km/h) corresponding to a Reynolds number
based on the height of the rain gutter and a Mach number of 60 000
and 0.13 respectively and a medium turbulence intensity were
imposed. Pressure outlet was applied at the outlet, while symmetry
was applied at the top and periodic conditions were applied on the
sides. The boundary layers was fully resolved with a y+ = 1, with a
first cell of 12 m at the wall. The height of the rain gutter is
about 20 mm. The time-step used for the unsteady DES simulations
was 5 s.
3.2.2. Steady 3D cases
To get information on the flow topology, steady RANS
computations were performed on the 4 cases. The tunnel open jet
section and the space around the model were reproduced for the
computation. The mesh was then composed of 2 domains linked by a
GGI interface. The core domain was meshed with a low Reynolds mesh,
while a coarse mesh was used for the outer domain. Fig 6 and Table
1 gives information on the computational domain and the size of the
meshes. An averaged velocity profile was given at the inlet to get
a boundary layer thickness in front of the rain gutter in the same
order as in the experiment. Three inlet velocities were tested (30,
45 and 60 m/s); table 2 gathered the Reynolds number
corresponding.
Fig. 6: Computational domain dimensions and Mesh Overview
Table 1: Number of nodes for each configuration Profile 1
Profile 2
Conf. Linear Inner: 4 520 000 nodes (6 070 000 in total) Inner:
4 900 000 nodes
(6 500 000 in total)
Conf. Curved Inner: 4 590 000 nodes (5 960 000 in total) Inner:
4 520 000 nodes
(5 910 000 in total)
Table 2: Reynolds number based on the rain gutters height for
the 3 studied sections Inlet Velocity Rain gutter 1 Rain gutter
2
0,66 H1 H1 1,6 H1 0,61 H2 H2 1,67 H2 30 m/s 26 500 40 000 64 000
22 500 36 000 60 500 45 m/s 40 000 60 500 97 000 33 500 54 000 90
500 60 m/s 53 000 80 500 129 000 44 500 72 500 121 000
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3.2.3. Unsteady 3D case (Profile 1 with height variation)
Due to the low resolution of the previous meshes in the
span-wise direction, acceptable unsteady results could not be
expected. At the opposite a complete refinement in the span-wise
direction of the mesh would not be realistic as it would lead to
far too high number of nodes. It was then decided to only compute
the unsteady flow in a 100 mm wide box centred on the middle
section of the rain gutter. Due to the slope, no periodic
conditions or symmetry were acceptable; therefore the chosen
alternative was to use interfaces. Three domains with GGI
interfaces were then created. The core domain consists in a 7 000
000 hexahedral block structured mesh. The maximum size of the cells
is 10.3 mm, allowing theoretically a spatial resolution of
wavelength of 21 mm i.e. 16 kHz. The second and the outer domains
were respectively composed of 1 120 000 and 273 000 nodes leading
to an overall number of nodes of 8 400 000. A hybrid scheme was
used for the convective terms, which automatically switches from
second order upwind in RANS regions to second order central
differencing in scale-resolved flow regions. The time-step used for
the simulations was set to a value of 10 s, maintaining a Courant
number around 1. Thus, an averaged velocity profile corresponding
to 45 m/s, as well as a turbulence viscosity ratio given at the
inlet, and an averaged static pressure at the outlet. The flow was
simulated on about 50 ms.
Fig. 7: Computational CFD domain and zoom on the mesh in the
core domain
4. Results and discussion
4.1. Comparison between the two profiles
Fig 8: representation of the structure for both profiles with a
stream flow at 45 m/s.
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Fig 8 gives a representation of the unsteady (computed with DES)
and a steady flow for both profiles. The pressure field is
represented on the side. Figures b) and d) represent the mean flow
using streamlines and the variable Q at 5106 s-2 was used to
represent the turbulent structures at a time step on (a) and (c).
The variable Q is defined as follow:
( )ijijijiji
j
j
i SSx
u
x
uQ =
=
21
21
As first comment, the site of the recirculation area is bigger
for the first profile. The level of turbulence and pressure
fluctuations appear also smaller behind the second profile. This
correlates well with the experimental results and tends to confirm
that the first profile is noisier than the second one.
4.2. 3D Steady Topology
The friction line patterns of the 3D linear configurations for
the part with the highest section for both profiles obtained
experimentally (oil visualisation) and from the simulations are
represented on fig.9. It can be seen that as expected, the size of
recirculation area in front and behind the rain gutter increase
almost linearly with its height. Close to the border of the rain
gutter (right side), the streamlines are highly deviated to the
exterior showing another 3D effect. Compared to the previous quasi
2D cases, the plate behind the rain gutter was a bit higher,
reducing the size of the recirculation and leading for the 2nd to
almost no recirculation behind the rain gutter. On the 2nd profile,
one also see the reattachment line occurred on the middle of the
thicker part of the rain gutter which is confirmed by the flow
visualisation.
Fig 9: Friction line pattern of the 3D linear configurations of
both profiles from experiments and numerical simulation
Fig 10 and Fig 11 present some more representation of the flow
for the different configurations. The red lines on fig. 10
represented the investigated section also presented on fig. 11. A
recirculation area having a length of about 6h (h being the rain
gutters height) could be found for the profile1. This value agrees
well with common value of 5 to 8 found in literature for forward
facing step. Looking from the top, it can also be seen that low
transverse effects occur in the linear cases while for the curved
configuration a slight deviation of the flow can already been seen
before the rain gutter.
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Fig. 10: Flow Topology of 3 different configurations: Profile 1
Linear (top, left), Profile 2 Linear (top, right), Profile 1 Curved
(bottom, left)
On the curved configuration, the inflow angle tends to reduce
the size of the recirculation and one can notice the formation of
the vortex on this configuration along the rain gutter which is not
without reminding the A-Pillar vortex. One can finally notice that
the height of the boundary layer in front of the rain gutter is
almost as high as the rain gutter itself.
Fig 11: Representation of the evolution of the flow topology
against the height (Profile 1 and 2) and against the flow angle and
the inlet velocity for the profile 1
4.3. Unsteady 3D case 4.3.1. 3D flow structures
According to Rung et al. [16], the numerical simulation requires
~12 time steps per oscillation period to accurately represent the
harmonic disturbances which gives here a limitation of a maximum
frequency of 8 333 Hz. The minimum frequency expected is 20 Hz (T =
50ms). Simulations with SAS-SST, DES and LES models conducted on
the same grid. Using the conventional SAS-SST implemented in ANSYS
CFX, the simulations was enable to switch to any unsteady mode and
always results in a steady solutions (fig. 13 a). In comparison
using DES or LES models, the structures behind the rain gutter
could be resolved (fig.14). Looking
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at the DES blending functions, it was also controlled that the
core domain was running in LES mode around the rain gutter.
Compared to the simulations on the quasi 2D cases (fig. 8) also
computed with DES, the structures in front of the rain gutter could
not be so well caught although similar span-wise resolution was
used. One element of explanation for this difference can be the
higher thickness of the boundary layer in this case which tends to
damp the instabilities and does not generate resolved turbulence
before the rain gutter.
Fig. 13 Visualisation of the turbulent structures using
isosurface of Q (Q =5106 s-2) shaded with velocity simulated with
the SAS model without (left) and with (right) forcing
Fig. 14 Visualisation of the turbulent structures using
isosurface of Q (Q =5106 s-2) shaded with velocity simulated with
DES (left) and LES (right)
This reason was also advanced to explain the unability of the
SAS-SST model to switch to unsteady mode. To overcome this problem,
it was decided to use the SAS-F model with forcing terms recently
introduced by Menter [17]. The idea is to introduce forcing terms
in the momentum equations in order to transfer modelled turbulence
energy into the resolved energy for flows which does not exhibit
sufficient strong instability to switch to unsteady mode. A volume
stochastic source term and sink term are then respectively
introduce in the momentum equations and modelled turbulent k in a
confined user-specified flow region. In this test-case, the zone
corresponds to the volume in the core domain in front of the rain
gutter. The computation was done with ANSYS Fluent 12 and the
results presented on fig13b shows that the structures in front and
behind the rain gutter could then be resolved.
4.3.2. Surface Sound Pressure Level
The experimental and computed with DES and SAS-F spectra for 3
flush-mounted microphones are represented on fig. 15. Microphones 1
and 5 were outside the core domain. At point 2, both models could
not catch the pressure fluctuations so far (83 mm) in front of the
rain gutter confirmed by fig13 and 14. At point 3, the SAS-F
presents a fair agreement with the experimental results while for
the DES simulations, the spectrum is very low confirming the
unability of the model to catch the fluctuations in front of the
rain gutter. For
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point 4, the SAS-F presents again a good agreement with the
experiment. The results of the DES simulations are only up to 1-3
kHz in good agreement with the experiment. After 3 kHz, on all DES
spectra, a brutal variation of the slope can be observed which
might indicate a cut-off frequency due to the mesh (~ 1mm). This
would also tend to confirm the lower dependency of the SAS model to
the size of the mesh.
Fig 15: Spectra for the middle section (Umean =45m/s); Point 2
(left), Point 3 (Middle) and Point 4 (right)
5. Information Computational Aeroacoustics
The high resolution level and long simulation time required for
getting the spectrum or the pressure fluctuations in the far field
made the direct approaches not usable for industrial applications.
Therefore hybrid approaches separating flow and acoustic simulation
appears more appropriate for such application. This work will be
the focus on a further paper which will be presented at the
Euronoise conference 2009, however few insights will be presented
here. + The first method already applied to a duct [18, 19]
consists of firstly computing a steady
flow solution and then an unsteady aeroacoustic field by
injecting a vortex [20] in the linearised Euler equations or to
model the acoustic sources by a stochastic modelling [21].
+ The other alternative is to compute the acoustic field by
using the results of the unsteady CFD simulations. Derived of the
original approach developed by Sir Lighthill in 1952, the software
Actran/LA [22] developed by FFT allows us to compute the Lighthill
sources from the unsteady variables (p, , U) and then to compute
the sound propagation. A coupling between CFX & Fluent with FFT
Actran is already available.
The 2D sound field computed for both profiles are represented on
fig 16. The first profile is the noisiest which is confirmed by the
spectra computed for both geometries.
Fig. 16: Computed Acoustic field and Spectra using respectively
injection vortex method and Stochastic modelling for both profiles
(2D computations)
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6. Conclusions In this study, the topologies of simplified 3D
configurations of A-pillar rain gutter have been investigated using
steady and unsteady flow simulations. The 1st profile presents the
highest level of turbulence and the higher noise level. It was
clearly shown the difficulty to get the unsteady flow structures
particularly in front of the rain gutter. The addition of the
forcing terms in the SAS-SST model turns out to be necessary in
this case and allows getting good agreements with the experimental
results. At the opposite, the DES simulations could only catch the
structure after the separation. The authors would also point out
that only short simulation times were performed and that longer
simulation times would allow to smooth the spectra and to improve
their quality to be compared with the experiment. Further work
particularly on the acoustical part will conducted and will be
presented in a further paper.
7. Acknowledgement The authors would like to thank M. Menter and
M. Mller from ANSYS Germany for their advice and contributions in
the CFD part as well as Prof. Delfs and M. Pott-Pollenske for their
advice on the experimental part.
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AIAA05-3015
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