Aerodynamic Development of the Ford Kuga
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Aerodynamic Development of the Ford Kuga The importance of vehicle aerodynamics is ever increasing due to its positive contribution to fleet fuel economy and high range in electric driving mode. The aerodynamic development of the Ford Kuga is a good example of how modern processes and technologies can deliver on high expectations. The cD values of the entire product palette were significantly reduced compared to its predecessor.
TARGET SETTING FOR PRODUCT DEVELOPMENT
It was clear from the early stages of the project that optimized aerodynamics would play an important role in delivering the desired product qualities. Good cD values should not be reserved only for a special version, the so-called Aero Leader, but be achieved by all variants. FIGURE 1 shows the principle used to set targets during the early phases of the project. The data show the progressive development with time of the cD values of SUVs and off-road vehicles from global manu-
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facturers. The diagram also shows a trend line for vehicles with Kuga-like silhouettes and similar aerodynamically relevant content. The values for the predecessors and most important competitors are marked out. In general, both the trend and the variance are reducing as time goes on. Good aerodynamics has also become highly valued due to the strong increase in oil prices starting in 2000 as well as globally tougher emissions standards from about 2010. To arrive at a cD target, the intended fuel economy and performance, the requirements of the package team as regards for example interior measure-
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AUTHORS
Dr.-Ing. Thomas Eberz is Supervisor Aerodynamic and Roadload Development at Ford-Werke GmbH in Cologne (Germany).
Dr. Philip Newnham is Responsible Engineer for the Aerodynamic Development and Homologation of the Ford Kuga at Ford-Werke GmbH in Cologne (Germany).
0.42 Ford Kuga F C Competitor EU&NA SUV/CUV
0.40 0.38 cD value [-]
ments, and the technology level improvements indicated by the trend line were weighed up against one nother. At the end of the process, a drag coefficient target of cD < 0.33 was decided for the majority of the global Kuga fleet. Specific variants with special off-road requirements (increased ride height, special underbody protection, off-road tires) were allowed to reach a maximum value of cD = 0.35. The components needed to reach the aerodynamic target, for example cooling airflow management by means of an active grill shutter, underbody panels and wheel spoilers, as well as the associated financial implications were defined and decided upon.
Tends to use le less aero measures
0.36 0.34 0.32 Tends to use more aero measures
0.30 0.28 2004
2006
2008
2010
The basic principles of the aerodynamic development process shown in FIGURE 2 are well understood [1]. The most important is a closely integrated development process involving designers, body engineers and aerodynamicists to arrive at an attractive and aerodynamic product. The ever-increasing number of variations and shorter development times require however that processes ar
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