Ford has harnessed cutting-edge wind tunnel technology, along with a vehicle-sized treadmill, to elevate the design of its upcoming production vehicles, including the all-new Mustang Dark Horse. With the Rolling Road Wind Tunnel (RRWT) capable of emulating wind and road speeds of 200mph (320kph), Ford is advancing efficient and high-performance vehicle testing across its lineup, encompassing electric, hybrid, and gas models.
Unlike previous wind tunnel designs, the RRWT provides more accurate data on wind drag and downforce, crucial elements for optimizing range and efficiency. Additionally, the system enables in-house testing replicating real-world road conditions, enhancing cost efficiency and design acceleration.
John Toth, North America Wind Tunnels Engineering Supervisor, highlighted the tunnel’s capabilities, stating, “The closer we can get to reality in the lab, the better and faster we can create more energy-efficient vehicles with great on-road and track stability.”
The RRWT introduces a novel five-belt rolling road system that simulates real-world drag, revolutionizing testing methodologies. By placing each wheel on a separate belt, and a large fifth belt beneath the vehicle, Ford can simulate road conditions accurately. This innovative approach optimizes aerodynamic performance testing, especially for high-speed vehicles like the Mustang Dark Horse.
The Mustang Dark Horse, a prime candidate for this wind tunnel testing, showcases tailored aerodynamics that contribute to its high-performance attributes. While efficiency-driven vehicles prioritize low drag, vehicles like the Mustang Dark Horse prioritize increased downforce for enhanced track performance and handling.
Equipped with features such as a Gurney flap and strakes, the Mustang Dark Horse generates additional downforce to enhance cornering and road adherence. The vehicle’s redesigned front bumper, lower valence, spoiler, and unique wheels further contribute to its aerodynamic prowess.
Jonathan Gesek, Program Aerodynamicists for Mustang and Bronco, highlighted the extensive wind tunnel work, stating, “We spent approximately 250 hours in the wind tunnel developing the 2024 Ford Mustang which includes Dark Horse. The aerodynamics of Mustang Dark Horse, along with several other factors, have created the most track- and street-capable 5.0-litre Mustang to date.”
Ford’s RRWT marks a significant step towards refining vehicle aerodynamics, with the Mustang Dark Horse serving as a testament to the success of this innovative approach.