Development of a Long Truck Roof Fairing Using CFD Simulations

Due to the recent industrial development in Sri Lanka, Transportation of commercial cargo has become a vital
necessity for the economic aspects. Considering the economic advantage of handling a larger crate of cargo
in a single journey, Semi-trailer trucks have become the most prominent long-distance transport mode in the
country. Apart from the frictional drag of the road resistance, the main considerable drawback of the semi-
trailer trucks is their unfavorable aerodynamic drag which directly contributes to a higher level of fuel
consumption (Frank & Turney, 2016). In tractor-trailer configuration, aerodynamic drag occurs mainly due to
the shape of the cabin, transition gap between the tractor, underbody of the truck and rear edge of the trailer
(Curry et al., 2012).

Roof fairing is one of the most common equipment used in Sri Lanka in order to overcome this aerodynamic
drag of a semi-trailer trucks where It directs the airflow smoothly over the top of the cabin and body of the
trailer. (Cooper 2003, Leuschen & Cooper 2009, Malviya et al., 2009). The main purpose of the research was
to evaluate the performance efficiency of different roof fairing shapes that are commonly used in Sri Lanka
using a computational fluid dynamics(CFD) analysis to identify the most important design characteristic which
involves in drag reduction. Aerodynamic analysis can be done in analytical, experimental or in numerical
methods (Hertz & Ukrainetz, 1967). It’s not practically feasible to experiment a larger truck geometry in a wind
tunnel and obtain an experimental value. Therefore, the CFD analysis is the most practically feasible method
for the objective. Researchers used the analysis to introduce a roof fairing shape which has better
aerodynamic characteristic. Outcomes of this research will be helpful to manufacture a low cost and
affordable roof fairing shape for the local market which is more efficient in reduction of drag in order to reduce
other financial factors such as fuel consumption.

Frank, T. and Turney, J. (2016). Aerodynamics of Commercial Vehicles. In: A. Dillmann and A. Orellano, ed.,
The Aerodynamics of Heavy Vehicles III, 79th ed. Springer, pp.196-210.

Cooper, KR. (2003). Truck aerodynamics reborn: lessons from the past. SAE Pap. 2003-01-3376, SAE
Int., Warrendale, PA.

Leuschen J., Cooper KR. (2009). Summary of full-scale wind tunnel tests of aerodynamic drag-reducing
devices for tractor-trailers

Malviya V., Mishra R., Fieldhouse J. (2009). CFD investigation of a novel fuel-saving device for
articulated tractor-trailer combinations. Eng. Appl. Computational Fluid Mechanics. 3:587-607
Hertz, P. and Ukrainetz, P. (1967). Auto-aerodynamic drag-force analysis. Experimental Mechanics, 7(3).

Curry, T., Liberman, I., Hoffmann-Andrews, L. and Lowell, D. (2012). Reducing Aerodynamic Drag &
Rolling Resistance from Heavy-Duty Trucks: Summary of Available Technologies & Applicability to
Chinese Trucks. Manchester: M.J. Bradley & Associates LLC.

Semi-trailer truck configuration was modelled in a 1:1 scale using a blueprint of a popular prime mover in Sri
Lanka. Blueprint which were published by the manufacturer was used to model the truck and initial
simulations were done using only the tractor and trailer configuration without attaching the modelled roof
fairing shapes. Researchers identified the importance of having the basic model coefficient of drag values
closed to the experimental values that was published by the manufacturer After modelling the long truck
structure without the roof fairing which obtains coefficient of drag values closer to the which were provided
by the truck manufacturer, the modelled roof fairing shapes were attached, and simulations were done.
Simulations were performed for three different inlet velocities using OPENFOAM computational fluid
dynamics software. Inlet velocities were selected considering the speed ranges in Sri Lanka. The efficiency of
the different roof fairings was analyzed in the post processing phase based on the parameters such as
coefficient of drag, percentage of drag reduction relative to truck without fairing and the main design
characteristics which were considered during the post processing were the horizontal deflection angle,
vertical deflection angle and the basic geometry of the roof fairing. Other parameters such as coefficient of
lift and moment were also considered in the analysis phase. A percentage reduction between 10 – 30% was
obtained for the different roof fairing shapes and It was found out that basic geometry and the vertical
deflection angle of a particular roof fairing provides a higher impact in drag reduction. The most prominent
parameter which was identified by the researchers was the basic geometry of the rood fairing. It was
understood that the curvy surfaces of the roof fairing have a major impact in drag reduction specially the
inbuilt structure of having pathways in the side panels allows a smooth transition of air flow around the roof
fairing to reduce the aerodynamic drag. Outcomes of this research will be helpful to manufacture a low cost
and affordable roof fairing shape for the local market which is more efficient in reduction of drag in order to
reduce other economical factors such as fuel consumption.