Ford has developed a state-of-the-art Rolling Road Wind Tunnel (RRWT) that allows for better aerodynamic research and development for the next generation of Ford electric, hybrid and gas vehicles.
The wind tunnel’s rolling road surface is capable of reaching wind speeds of up to 200 mph so that aerodynamicists can simulate road or track conditions, helping research and development. Allows further development.
The rolling road wind tunnel was used to aid in the development of the all-new Mustang® Dark Horse™, which has the highest downforce of any 5.0-liter Mustang when equipped with the available Handling Package, allowing the vehicle to handle the road and The track helps to stick to the ground in both places.
Dearborn, May, June 13, 2023 – Wind tunnels have long been used to design and test aerodynamic and energy-efficient vehicles. Now Ford has combined the latest wind tunnel technology with a car-sized treadmill to help build its next-generation production vehicles, including the all-new Mustang Dark Horse.
Ford’s latest rolling road wind tunnel:
Meeting the road and the vehicle With the ability to simulate wind and road surface speeds up to 200 mph, the Rolling Road Wind Tunnel (RRWT) supports testing for efficient and performance-oriented vehicles across the Ford lineup – including the next Generation Ford electric, hybrid and gas vehicles are also included.
“The amount of air transferred through our wind tunnel is enough to fill a K-class airship in just 5 seconds.” – John Toth, North America Wind Tunnels Engineering Supervisor.
A key advantage of the RRWT is that it provides more accurate data than earlier wind tunnel designs in terms of both wind shear and downforce, which are key factors for improving range and efficiency. It also allows for more in-house tests that simulate open road conditions, which can help reduce design costs as well as speed up the design process.
“The closer we can get to reality in the laboratory, the better and faster we can develop more energy-efficient vehicles with excellent road and track stability,” Toth said. “On-the-fly testing of vehicle wheels and tires are essential to optimizing aerodynamics for track-ready vehicles like the Mustang Dark Horse, which must balance both downforce and downforce.”
A new five-belt rolling road system can mimic real-world downforce through a rolling road aerodynamic tunnel that allows Ford to bring the road to the car rather than the car on the road.
For full aerodynamic efficiency testing, each wheel gets its own individual strip, which consists of the first four strips. A large fifth strip runs down the center of the vehicle. The crane is used to switch between five-strip and single-strip systems – an industrial-sized plug-and-play system. The single track – which runs up to 200 mph – introduces a new type of testing for high-speed performance vehicles.
Maximizing Downforce on a Misting Dark Horse
The Mustang Dark Horse is one of the first several vehicles to be tested in this wind tunnel.
An important factor in the development of new vehicles is to adapt their aerodynamics as needed.
Achieving minimal downforce is important for general passenger cars and trucks to maximize fuel efficiency. However, in models where performance on the track is a priority, such as the Mustang Dark Horse, aerodynamicists strive to maximize downforce rather than minimize downforce. Downforce helps keep the vehicle steek (sticking) to the road or track and improves control in sharp turns.
The Misting Dark Horse is also available with an optional Gurney flap, which is an additional plate attached to the rear wing that helps generate more downforce. In addition, the front of the car has three vertical plates (strakes) near each front wheel that affect the airflow to create more downforce on the underside of the car. This helps to keep the car more steek (sticky) when cornering at high speed on the road.
Overall, the Mustang Dark Horse features several changes and additional features, including a redesigned front bumper, lower valence, a spoiler, and unique wheels. The front design is designed to increase airflow for engine cooling, braking and air intake, while also reducing front lift. The Misting Dark Horse has a unique lower mounted air spoiler and splitter that allows the vehicle to adjust for more downforce. The upgraded handling package on the Dark Horse provides a unique splitter, spoiler and wheels – these changes may seem small, but when it comes to performance, they make all the difference when driving on the road or track.
“We spent nearly 250 hours in the wind tunnel developing the 2024 Ford Mustang, including the Dark Horse,” said Jonathan Gazik, Mustang and Bronco program aerodynamics specialist. “Musting dark horse aerodynamics and several other factors have created the most track- and street-capable 5.0-liter Mustang to date.”