Wind tunnels are machines where an object is held stationary inside a tube, and air is blown around it to study the interaction between the object and the moving air. They are used to test the aerodynamic effects of aircraft, rockets, cars, and buildings. Different wind tunnels range in size from less than a foot across, to over 100 feet (30 m), and can have air that moves at speeds from a light breeze to hypersonic velocities.
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Usually, large fans move air through the wind tunnel, while the object being tested is held stationary. The object can be an aerodynamic test object such as a cylinder or an airfoil, an individual component of an aircraft, a small model of the vehicle, or, in the largest tunnels, even a full-sized vehicle. Different measurements can be taken from these tests. The aerodynamic forces on the entire object can be measured, or on individual components of it. The air pressure at different points can be measured with sensors. Smoke can be introduced into the airstream to show the path that air takes around the object. Or, small threads can be attached to specific parts to show the airflow at those points.
The earliest wind tunnels were invented towards the end of the 19th century, in the early days of aeronautical research, as part of the effort to develop heavier-than-air flying machines. The wind tunnel reversed the usual situation. Instead of the air standing still and an aircraft moving, an object would be held still and the air moved around it. In this way, a stationary observer could study the flying object in action, and could measure the aerodynamic forces acting on it.
The development of wind tunnels accompanied the development of the airplane. Large wind tunnels were built during World War II, and as supersonic aircraft were developed, supersonic wind tunnels were constructed to test them. Wind tunnel testing was considered of strategic importance during the Cold War for development of aircraft and missiles.
Other problems are also studied with wind tunnels. The effects of wind on man-made structures need to be studied when buildings became tall enough to be significantly affected by the wind. Very tall buildings present large surfaces to the wind, and the resulting forces have to be resisted by the building's internal structure or else the building will collapse. Determining such forces was required before building codes could specify the required strength of such buildings and these tests continue to be used for large or unusual buildings.
Starting in the 1960s,[1] wind tunnel testing was applied to automobiles, not so much to determine aerodynamic forces in the same way as an airplane, but to increase the fuel efficiency of vehicles by reducing the aerodynamic drag. In these studies, the interaction between the road and the vehicle plays a significant role, and this interaction must be taken into consideration when interpreting the test results. In the real world, the vehicle is moving while the road and air are stationary. In a wind tunnel test, the road must also be moved past a vehicle along with air being blown around it. This has been accomplished with moving belts under the test vehicle to simulate the moving road, and very similar devices are used in wind tunnel testing of aircraft take-off and landing configurations.
Sporting equipment has also studied in wind tunnels, including golf clubs, golf balls, bobsleds, cyclists, and race car helmets. Helmet aerodynamics is particularly important in open cockpit race cars such as Indycar and Formula One. Excessive lift forces on the helmet can cause considerable neck strain on the driver, and flow separation on the back side of the helmet can cause turbulent buffeting and thus blurred vision for the driver at high speeds.[2]
The advances in computational fluid dynamics (CFD) modelling on high-speed digital computers has reduced the demand for wind tunnel testing, but has not completely eliminated it. Many real-world problems can still not be modeled accurately enough by CFD to eliminate the need for physical tests in wind tunnels.
Danish inventor Poul la Cour applied wind tunnels in his process of developing and refining the technology of wind turbines in the early 1890s.Carl Rickard Nyberg used a wind tunnel when designing his Flugan from 1897 and onwards.
The Wright brothers' use of a simple wind tunnel in 1901 to study the effects of airflow over various shapes while developing their Wright Flyer was in some ways revolutionary.[10] It can be seen from the above, however, that they were simply using the accepted technology of the day, though this was not yet a common technology in America.
Between 1909 and 1912 Eiffel ran about 4,000 tests in his wind tunnel, and his systematic experimentation set new standards for aeronautical research.In 1912 Eiffel's laboratory was moved to Auteuil, a suburb of Paris, where his wind tunnel with a two-metre test section is still operational today.[11] Eiffel significantly improved the efficiency of the open-return wind tunnel by enclosing the test section in a chamber, designing a flared inlet with a honeycomb flow straightener and adding a diffuser between the test section and the fan located at the downstream end of the diffuser; this was an arrangement followed by a number of wind tunnels later built; in fact the open-return low-speed wind tunnel is often called the Eiffel-type wind tunnel.
The US Navy in 1916 built one of the largest wind tunnels in the world at that time at the Washington Navy Yard. The inlet was almost 11 feet (3.4 m) in diameter and the discharge part was 7 feet (2.1 m) in diameter. A 500 hp (370 kW) electric motor drove the paddle type fan blades.[12]
In 1931 the NACA built a 30 by 60 feet (9.1 by 18.3 m) full-scale wind tunnel at Langley Research Center in Langley, Virginia. The tunnel was powered by a pair of fans driven by 4,000 hp (3,000 kW) electric motors. The layout was a double-return, closed-loop format and could accommodate many full-size real aircraft as well as scale models. The tunnel was eventually closed and, even though it was declared a National Historic Landmark in 1995, demolition began in 2010.
In 1941 the US constructed one of the largest wind tunnels at that time at Wright Field in Dayton, Ohio. This wind tunnel starts at 45 feet (14 m) and narrows to 20 feet (6.1 m) in diameter. Two 40-foot (12 m) fans were driven by a 40,000 hp electric motor. Large scale aircraft models could be tested at air speeds of 400 mph (640 km/h).[15]
During WWII, Germany developed different designs of large wind tunnels to further their knowledge of aeronautics. For example, the wind tunnel at Peenemünde was a novel wind tunnel design that allowed for high-speed airflow research, but brought several design challenges regarding constructing a high-speed wind tunnel at scale. However, it successfully used some large natural caves which were increased in size by excavation and then sealed to store large volumes of air which could then be routed through the wind tunnels. By the end of the war, Germany had at least three different supersonic wind tunnels, with one capable of Mach 4.4 (heated) airflows.
A large wind tunnel under construction near Oetztal, Austria would have had two fans directly driven by two 50,000 horsepower hydraulic turbines. The installation was not completed by the end of the war and the dismantled equipment was shipped to Modane, France in 1946 where it was re-erected and is still operated there by the ONERA. With its 26 ft (8 m) test section and airspeed up to Mach 1, it is the largest transonic wind tunnel facility in the world.[16]
On 22 June 1942, Curtiss-Wright financed construction of one of the nation's largest subsonic wind tunnels in Buffalo, NY. The first concrete for building was poured on 22 June 1942 on a site that eventually would become Calspan, where the wind tunnel still operates.[17]
By the end of World War II, the US had built eight new wind tunnels, including the largest one in the world at Moffett Field near Sunnyvale, California, which was designed to test full size aircraft at speeds of less than 250 mph (400 km/h)[18] and a vertical wind tunnel at Wright Field, Ohio, where the wind stream is upwards for the testing of models in spin situations and the concepts and engineering designs for the first primitive helicopters flown in the US.[19]
Later research into airflows near or above the speed of sound used a related approach. Metal pressure chambers were used to store high-pressure air which was then accelerated through a nozzle designed to provide supersonic flow. The observation or instrumentation chamber ("test section") was then placed at the proper location in the throat or nozzle for the desired airspeed.
In the United States, concern over the lagging of American research facilities compared to those built by the Germans led to the Unitary Wind Tunnel Plan Act of 1949, which authorized expenditure to construct new wind tunnels at universities and at military sites. Some German war-time wind tunnels were dismantled for shipment to the United States as part of the plan to exploit German technology developments.[20]
For limited applications, computational fluid dynamics (CFD) can supplement or possibly replace the use of wind tunnels. For example, the experimental rocket plane SpaceShipOne was designed without any use of wind tunnels. However, on one test, flight threads were attached to the surface of the wings, performing a wind tunnel type of test during an actual flight in order to refine the computational model. Where external turbulent flow is present, CFD is not practical due to limitations in present-day computing resources. For example, an area that is still much too complex for the use of CFD is determining the effects of flow on and around structures, bridges, and terrain.
There are many applications for boundary layer wind tunnel modeling. For example, understanding the impact of wind on high-rise buildings, factories, bridges, etc. can help building designers construct a structure that stands up to wind effects in the most efficient manner possible. Another significant application for boundary layer wind tunnel modeling is for understanding exhaust gas dispersion patterns for hospitals, laboratories, and other emitting sources. Other examples of boundary layer wind tunnel applications are assessments of pedestrian comfort and snow drifting. Wind tunnel modeling is accepted as a method for aiding in green building design. For instance, the use of boundary layer wind tunnel modeling can be used as a credit for Leadership in Energy and Environmental Design (LEED) certification through the U.S. Green Building Council.
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