A commercial CFD program and boundary layer analysis are used to design the inlet of an open circuit wind tunnel for aerodynamic testing of full scale, class eight trucks. The goal of the study is to obtain the combination of wall shape, contraction length, and setting screens that provide a uniform velocity profile upstream of the vehicle under test. Thwaites method is used to verify that the boundary layer does not separate. Velocity field predictions upstream of the vehicle under test are presented for different design configurations of the inlet. A variation in the velocity magnitude of less than one percent outside of the boundary layer is achievable. The contraction introduces a weak secondary flow in the corners of the wind tunnel, but the cross stream components do not lead to significant distortion of the axial profile.

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