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Based on a new-energy sedan as the research object, the Design of Experiments (DOE) optimization integrated grid deformation method was used to optimize and improve the aerodynamic performance of a certain development model. A three-dimensional flow field comparison analysis was conducted on the improved areas of the whole vehicle flow field, and wind tunnel tests were conducted for verification. Through CFD simulation and wind tunnel test verification, the accuracy of the CFD simulation method was verified. The engineering feasible DOE optimization recommended area for the whole vehicle was summarized. The optimal prediction results based on the DOE optimization method and the corresponding CFD simulation results were analyzed for reliability. The correlation between the optimization variables and the target function was analyzed, and 6 counts reduced the whole vehicle drag coefficient by adjusting the optimization variables within a small range. Finally, wind tunnel tests were used to verify the effectiveness of the optimized variable scheme. The results provide an important reference for the optimization design and development of vehicle aerodynamic performance.

In the developmental phase of an electric SUV model, optimizing the SUV model’s aerodynamic performance often involves the use of wheel deflectors to control airflow around the front wheels. While lamellar wheel deflectors are a common choice for reducing aerodynamic drag, the automotive industry is increasingly embracing 3D wheel deflectors to enhance drag reduction efforts. This study delves into the flow patterns surrounding the front wheels and the drag reduction mechanisms brought about by wheel deflectors. In this research, we harness the strengths of both lamellar and 3D wheel deflectors to introduce a more effective design approach. The conceived wheel deflectors aim to simultaneously decrease aerodynamic drag and lift, a dual-purpose strategy that extends the SUV’s range and optimizes its stability at high speeds. To validate these optimization effects, comprehensive Computational Fluid Dynamics (CFD) simulations and subsequent wind tunnel testing are conducted. The findings presented in this paper establish a crucial foundation for the design and optimization of wheel deflectors, contributing to advancements in the field.