Theme 2: Multi-Physics and Multi-Functional Simulation Methods.

The multi-physics theme is a programme of linked activities that improve the simulation capability within the Automotive Design and Engineering process. It is intended that the methods will have application across a wide range of functions, dynamics and attributes of the vehicle. For example; the off-road capability, the effects off real world aerodynamics and the modelling of the noise within the passenger compartment. The ability to apply simulation methods from initial concept through to engineering verification allows robust decision making at all stages of the process. This will shorten product development times, improve flexibility and the ability to respond to market pressures, reduce reliance on physical prototypes and reduce costs and improve competitiveness. The simulation capability will therefore be expanded both in breadth and depth and methods for making simulation tools available throughout the design and engineering process will be explored.
The multi-physics theme is structured around three common research challenges associated with the modelling of complex phenomena in an Automotive context; Reduced Order Modelling, Coupling, and High Fidelity Modelling. These are pursued through several specific projects that address different aspects of the vehicle. By addressing multiple functions within a single proposal there is considerable added value through both academic cross-fertilisation and in cross-attribute collaboration within JLR.
The three main research challenges are:
High Fidelity Modelling; here refers generally to the simulation of complex phenomenon, for example, capturing the time dependent flow-field around a vehicle where the simulation must accurately resolve the physical processes. An alternative example is capturing the complex tyre-terrain interaction that occurs in an off road situation.
The coupling challenge is associated with connecting multiple simulations in terms of the physics and also the process of timing and communication. The emphasis here is on the physics. In addition, the coupling challenge refers to the connection between large simulations running on an high performance computing system and simpler reduced models that are designed to capture only the most important aspects of the physics, for example between a full computational simulation of the in-cylinder flow and a simple model to predict the engine emissions.
A reduced order model can be a reduction of a much larger simulation or system of simulations that can be used, within prescribed limits, to investigate specific aspects of a design or to quickly optimise a design before escalating to higher order. Alternatively a reduced order model might be coupled with a higher order model. For example a high fidelity numerical simulation of the aerodynamics might be coupled with a reduced order vehicle handling model to investigate crosswind characteristics.
The work is organised into three packages, the first focuses on fluid dynamic driven aspects of simulation and comprises three projects: Real World Aerodynamics, Surface Contamination and Engine-out Emissions. The first undertakes high fidelity unsteady flow simulations of a dynamic vehicle in a realistic environment, the second modelling of surface contamination using the flow predictions from the first project and the third determines emissions based upon the flow-field in the cylinder prior to combustion. The second package focuses on the simulation of effects of rough terrain, through three projects: the prediction of terra-mechanics excitations and their effect on vehicle dynamics, the transmission to the passenger cabin in the form of noise vibration and harshness and their effect on fatigue failure of critical components. The third package will develop methods of automated model order reduction and will take as it cases work from across the theme, initially relatively simple slow-varying problems and then extending to more complex multi-nodal models.

The primary benefactor of this research is the automotive design and manufacturing industry where the implementation of multi-physics simulation will allow vehicles to be designed more rapidly with reduced physical verification and validation. This will result in a product with a faster time to market that meets customer expectations. Multi-physics simulation is also important where there are closely aligned research challenges, such as aerospace and nuclear engineering. The research is also of considerable interest to the academic community in a number of related fields where the projected outcomes from high fidelity models, automated reduced order modelling, and the coupling of multi fidelity models have applications more broadly across automotive, aerospace and nuclear engineering, but also in Chemical, Mechanical, Electrical and Systems Engineering.
This project is partly funded by Jaguar Land-Rover (JLR) who have been closely involved in developing the scope of the proposal and will continue to be involved throughout the lifecycle of the project. This close collaboration, chanelled through the JLR theme lead, will ensure that knowledge is transferred effectively throughout the duration of the work. This includes both specific modelling methods, for example of surface contamination, and reduced order models of, for example an aspect of crosswind stability, validation data and cases of coupling of high fidelity and reduced order models. The methods and software used in the project will be closely aligned with the practices of JLR through the JLR theme lead, so that advances can be incorporated into the industrial design process.
The primary impact of this work will be to increase the competitiveness of the UK automotive design and manufacturing sector so contributing towards increased wealth creation and economic prosperity. Additional considerations are; reduction of CO2 emissions, through improved aerodynamics and engine design and an improvement in road vehicle safety, through improved vision and improved off-road capability. Even small improvements in these two areas have a significant benefit to society and the economy.
Economic and societal impact of the outcomes of this project will be achieved through: a) close links with industry throughout the project; b) short secondments of researchers to JLR during the project; c) workshops open to industry and academics and d) a special edition of an international journal.
The Department of Aeronautical and Automotive Engineering at Loughborough has many strong research links and partnerships with other engineering companies including Lotus Engineering, Caterpillar, Intelligent Energy, BAE Systems and Rolls-Royce Civil Aerospace. This will allow outcomes from the project to be rapidly disseminated to research engineers in these companies. Wider impact will be sought through publication at international conferences.
Workshops will be held at the midpoint and end of the programme to which both academia and industry will be invited. These workshops will be used to showcase the three work packages and to elicit feedback and guidance.
Aligned with the proposal, eight PhD studentships will be funded directly by JLR (60%) and Loughborough University (40% through existing departmental studentship funds) and these will work together with the EPSRC funded PDRAs to achieve the project goals. Where feasible secondments of PDRA's and students at JLR will allow the research team to better understand the industrial practices that are relevant to the research and for the students to demonstrate the capability of their research on real vehicle problems. It is envisaged that many of these PDRA's and PhD students would, after graduation, be employed by JLR or other UK Automotive R&D organisations helping to close the UK gap in highly skilled engineers required by industry.