Driving Innovation at STEM Racing: How Ansys Powered Advanced Design, Aerodynamic Analysis, and Performance Simulation

“By integrating Ansys simulation tools into our engineering process, we unlocked a new level of innovation and validation for our STEM Racing project. Using Ansys Fluent software, our computational fluid dynamics (CFD) results closely aligned with those from our wind tunnel testing, confirming the accuracy and reliability of our aerodynamic refinements. Employing Ansys Mechanical software, we ensured our custom four-axis CNC machine’s design could withstand the operational stresses required for precise manufacturing.” 

— Aisas Tatsis
Team Leader and Engineer, PiForce

Engineering Solutions 

Using computational fluid dynamics (CFD) capabilities in Fluent software, the team was able to:

• Precisely model airflow, pressure distribution, and aerodynamic forces around the car designs
• Receive quick comparisons of multiple geometry variations, which enabled the team to refine shapes and improve aerodynamic efficiency
• Compare results with wind tunnel data, confirming that the CFD-driven improvements were accurate and reliable
• Incorporate Fluent results into the team’s custom software, providing a holistic view of each design’s overall performance and guiding data-driven decision-making

Ansys Mechanical software enabled the team to:

• Ensure their custom four-axis CNC machine’s components could withstand operational stress, securing its durability and precision
• Minimize reliance on physical prototypes, which not only shortens development time and optimizes material usage but also ensures that the construction withstands stress and strain effectively

Benefits

• By leveraging virtual testing, PiForce reduced design cycle times by approximately 40%, enabling them to refine concepts more rapidly than relying solely on physical prototypes.
• Engineering simulation helped identify key aerodynamic improvements, resulting in an estimated 12% increase in overall aerodynamic efficiency.
• Integrating simulation results into the team’s custom software provided precise, actionable insights, which enabled them to confidently select the fastest, most efficient design.
• Using professional-level simulation tools gave the team industry-relevant skills, enhancing their engineering knowledge and strengthening their competitive advantage.
• These optimizations and rapid iteration cycles translated into improved on-track performance, setting the team apart from others and directly contributing to their award-winning results.