Aerodynamics Simulation: Coupling CFD with MBD, FEA and 1D-System Simulation

Aerodynamics is a common application of CFD and one of the ESimLab team core areas of expertise. Studies can cover the full speed range of low speed, transonic, supersonic and hypersonic flows as well as turbulence and flow control. System properties such as mass flow rates and pressure drops and fluid dynamic forces such as lift, drag and pitching moment can be readily calculated in addition to the wake effects. This data can be used directly for design purposes or as in input to a detailed stress analysis. Aerodynamics CFD simulation with sophisticated tools such as Ansys Fluent and Siemens Star-ccm+ allows the steady-state and transient aerodynamics of heating ventilation & air conditioning (HVAC) systems, vehicles, aircraft, structures, wings and rotors to be computed with extremely high levels of accuracy.

CFD simulation offers the ability to conduct comprehensive, automated, multi-point optimization of designs. This process allows our engineers to optimize a design to a given set of performance parameters and can be used to minimize drag, or maximize mass flow or lift forces to given targets. ESimLab engineering team is providing effective solutions in optimizing lift to drag ratios and balancing overall performance with size.

CFD Aerodynamics Simulation include:

  • External Vehicle Aerodynamics
  • Internal flow
  • Sport equipment and athlete drag reduction, performance optimization.
  • Vortex Shedding
  • Structure Wind Load
  • HVAC Application

Better product development with advanced simulation.

We Could Develop New Software Based on Your Needs

Aerodynamics – CFD Analysis of Race Car

We provide Engineering Analysis of fluid flow over a body, wing or component with Star-ccm+ and Ansys Fluent. We can work from a drawing, CAD file or can scan the geometry of your car or component. A standard analysis includes a report including the following information:

Drag Force, Down Force, Drag Coefficient, Pressure Coefficient, Pressure Contour Plot, Velocity Contour, Velocity Streamlines

If the overall design has poor aerodynamic efficiency, flow separation could occur, which will have a negative effect on the rear wings down force levels and overall drag penalties. This will result in slower lap times due to decrease top speed on the straights, also braking and cornering capacities.

ESimLab engineering team can work to simulate and optimize all cmponent of race cars include:

  • Aerodynamic Suspension
  • Barge Boards and Guide Vanes
  • Drag Reduction System
  • Nose Cone
  • Rear Wheel Scallops
  • Side Pods
  • Under-tray
  • Winglets

Aerodynamic Simulations of Rotors by means of Coupled FEA (MBD) – CFD methods

The prediction of the flow around helicopters by means of CFD methods is one of the most challenging problems in aerodynamics. This is due to unsteadiness of the flow and the large number of flow phenomena which must be accurately resolved, e.g. the transonic flow regions on the advancing rotor blade, dynamic stall and reverse flow areas on the retreating blade, tip vortices of the main and tail rotors and their interaction with other rotor blades and the fuselage. The blade vortex interactions (BVI) generate high load peaks and represent one of the main noise sources of a helicopter. In contrast to the rotors the flow around the fuselage is basically incompressible and many helicopters have a blunt body with large flow separations behind the fuselage. Depending on the flight conditions there may be strong interactions between main and tail rotors, rotor head, fuselage and the empennage, e.g. the tail shake phenomenon which is mainly caused by separations behind the rotor head. 

In order to resolve accurrately the flow phenomena described above the solution of the unsteady Reynolds-averaged Navier-Stokes equations (URANS) with Fluent or Star-ccm+ is required with strong coupling procedure using the multibody simulation code such as MSC Adams and SIMPACK or FEA software such as Nastran and Abaqus. During one rotor revolution the unsteady airloads and centrifugal forces cause blade flapping and lead/lag motions as well as large aeroelastic blade deformations. A rotor trim procedure and a method to calculate the elastic deformations (FEM and MBD) are therefore needed to get the correct blade shape and to adjust the rotor controls for the desired flight state.

External Aerodynamics Simulation

From the design of a hyper car to regular family-SUV type cars aerodynamics play a crucial role, where ESimLab engineering team can support you throughout the entire process using sophisticated CFD tools such as Siemens Star-ccm+ and Ansys Fluent.

For every operating condition of the vehicle aerodynamics there is a key part where performance drives the vehicle shape. Key aspects analysed in external aerodynamics include:

  • Drag evaluation: Pressure, cooling
  • Cooling efficiency: Air leakage
  • Downforce optimization: Front end air flow

Internal Flow Aerodynamics Simulation

If your problem is an “internal flow” case, whereas the fluid is confined by walls in every direction, most important aerodynamic quantities involves pressure loss, friction, local velocity and turbulence. These quantities can be very well simulated and predicted for your product, way before it gets manufactured. This means cost and time savings for you.

Examples for internal flow aerodynamics applications:

  • pipe flows
  • duct flow in HVAC applications and building air-conditioning
  • turbomachinery
  • diffusors
  • nozzles
  • sudden contractions and expansions
  • valves
  • fittings
  • elbows in piping systems
  • heat exchangers
  • general industrial flows


CFD method is used to analyze and solves the problem related to Fluid Flows, computers are required to formulate the mathematical expression of interaction between liquid and gas with defined boundaries. It has wide applications in industries like automotive, part of Defense, Electrical and physical science, and Energy. CFD gives realistic and predictive insight in to Flow patterns & Thermal contours that are intended to solve complex engineering problems.

Equipped with multi-domain knowledge and deep technical expertise, ESimLab engineering team offers global strategic engineering and environmental consultancy that specializes in performing 1D-Multi-Physics CAE simulations.


With deep Knowledge in FEA and CFD and combining or coupling different CAE tools for real world simulation such as Ansys Fluent, Siemens Star-ccm+, Abaqus and MSC Nastran, Esimlab enginnering team can handle any aerodynamic problem include wind turbine and wind effect:

  • Vertical axis wind turbine: foil sections and blades design investigation and optimization
  • Horizontal axis wind turbine:

          – Blade planform, twist and airfoil section design, investigation and optimization
          – Hub and nacelle Interaction
          – Rotor and Tower Interaction

  • Power-Trust curves extraction and optimal working point estimation
  • Special tools for micro turbine innovative designs investigation
  • Complete motion of the rotor in winds and loads extraction for FEM analysis
  • Fluid-Structure Interaction (FSI) investigation and flutter occurence
  • Solar loads and radiation – solar collectors design
  • Underwater turbine


  • Atmospheric Boundary Layer (ABL) modelling and thermal loads
  • Full windrose estimation over complex terrain/buildings
  • Wind turbine siting investigation
  • Urban air quality
  • Smoke and Pollution dispersion
  • Wind loads over structures/buildings

Drone Aerodynamic Simulation

Drone aerodynamic simulation is used to improve the aerodynamic performance and reducing the drag of Drone. Objective of the simulation is to make accurate predictions of aerodynamic forces, Lift and Drag Coefficient etc.
While aerodynamics is at the core of all aerospace engineering programs, the broader discipline of fluid mechanics, encompassing both aero- and hydrodynamics, covers a vast array of topics. Esimlab engineering team use coupled MBD and CFD to simulate any Drone related problems in world class simulation methods.

Aerodynamic Noise Analysis

Sound caused by pressure oscillation of fluid, such as wind noise, and sound caused by resonance can be predicted using Large Eddy Simulation (LES) and a weak compressible flow model. A Fast Fourier Transform calculation can be used within the CFD software to predict the frequency of noise.

Predicting the noise generated by complex flows from steady CFD solutions allows us to study the noise generated by turbulent flows from CFD solutions. Combining CFD and acoustic simulation software for study aerodynamic noise sources from flow simulations performed with CFD codes such as Fluent, StarCCM+ or OpenFOAM enable us to use the results from flow simulation obtained from CFD analysis, for export to the acoustic simulation software to synthesize the noise sources. These sources are then imported into an acoustic computation and are then propagated. This procedure allows addressing the noise generated from turbulent flows in a much faster way than classic aero-acoustic approaches and it is specifically useful when relative levels between different designs are needed such as in optimization loops. ESimLab engineering team can cover VibroAcoustics and aero-vibro-acoustic challenges, also.

Sample applications:

  • Air conditioning modules (HVAC).
  • Side mirror noise.
  • Airframe noise (landing gear, trailing edge).
  • Air distribution systems.

Cabin Aerodynamics CFD Simulation

The passenger’s thermal comfort is an essential design-criterion for the air-conditioning and customization of a cabin. In industry, engineers conduct costly and time-consuming test series with specifically built cabin mock-ups to obtain some information about the expected passenger’s sensation of comfort already in the design process.

CFD Simulation can predict the passenger’s comfort by means of advanced software such as Star-ccm+ and Ansys Fluent and to allow for an interactive layout of an optimized cabin. The CFD-computations of the air flow in the cabin’s interior and the flow through cabin air outlets is optimized with the help flow simulations to achieve design specifications.

We help our customers with the analysis, design & optimization of flow related products and systems in a wide range of industries. We analyze and improve the performance of existing products, or we design new products from scratch based on the broad knowledge of our engineering team in the fields of product development, control system design, simulation, analysis, optimization and prototyping, but our knowledge in fluid flows is unique and sets us apart.

Advanced Technology

We resolve any type forming with the most detailed and accurate methodology

Reduce Development Cost

ESimLab FEA service enables you to ensure the manufacturability of parts in the design phase

Test Before Manufacturing

Applied from early on in the part design phase, we can investigate the part manufacturability and performance