FKFS Veranstaltungen

2025 FKFS Conference on Vehicle Aerodynamics

and Thermal Management

15 - 16 October 2025 | Leinfelden-Echterdingen

Session: Environmental Testing | | 13:00 - 13:30

Efficient Hybrid Approach for Vehicle Soiling Simulations

Kevin Posch, MAGNA STEYR Fahrzeugtechnik GmbH & Co KG

Mitigating vehicle soiling is crucial as it affects drivers’ vision and sensor functionality. Addressing this early in vehicle development requires advanced simulation techniques. Magna has developed a hybrid simulation approach integrated with wind tunnel tests, forming a core part of the aerodynamic development process. The initial phase involves a complete vehicle soiling simulation using a model with approximately 200 million cells to track boundary layer flow with a low Y+ approach and a Detached Eddy Simulation turbulence model. This detailed modeling captures near-wall regions accurately, essential for soiling simulations. A Lagrangian phase (water) is coupled one-way with the Euler phase (air), allowing simultaneous evaluation of aerodynamic and soiling performance. For specific regions, submodels are used, building on data from the complete vehicle simulation. These focus on localized phenomena, such as soiling on side mirrors and adjacent windows, requiring high modeling accuracy. Two additional Euler phases are introduced: the fluid film model and the Volume of Fluid model. This hybrid simulation approach is advantageous during early vehicle development phases with rapid iteration cycles. In summary, Magna's hybrid simulation technique, validated through wind tunnel tests, offers a robust and efficient solution during early development. It ensures vehicle aesthetics and the functionality of safety-critical sensors, enhancing driver safety and vehicle performance.