Design and validation of a 3-hole aerodynamic probe

This thesis presents the development and experimental validation of a custom, low-budget 3-hole aerodynamic probe. The primary objective of this system is to provide accessible, on-track data acquisition to validate extensive Computational Fluid Dynamics (CFD) analyses conducted on a late 1980s Formula Opel Lotus race car, which recently underwent significant aerodynamic upgrades including a newly designed floor, rear wing, and bargeboards. The project methodology seamlessly integrates aerodynamic simulation, custom electronics and rapid prototyping. Initially, CFD simulations were performed using OpenFOAM to design and optimize a single-hole Kiel probe, which demonstrated effective total pressure measurement at flow inclination angles of up to nearly 60 degrees. The geometry was subsequently expanded into a 3-hole configuration by incorporating two lateral ports to measure the yaw of the probe relative to the freestream airflow. This iteration allowed for the establishment of a precise correlation between the flow inclination angle and the differential pressure registered by the sensors. Both probe iterations were manufactured utilizing 3D printing technologies. The physical prototypes were then subjected to rigorous experimental calibration within a wind tunnel featuring a 200x200 mm test section. Concurrently, a microcontroller-based data acquisition system was developed and integrated to reliably log the sensor data. Ultimately, this integration of CFD, embedded electronics, and additive manufacturing yielded a functional, cost-effective acquisition system capable of being mounted directly onto a race car, providing critical empirical data to deepen the understanding of on-track vehicle aerodynamics.