Multiphase Fuel Tank Simulation Under Real Track Loads

I built a transient multiphase simulation (air and ethanol, with a full evaporation/condensation model between the liquid and gas phases) and drove it with real accelerometer data captured from the car during an actual competition lap — so the accelerations the fuel experiences in the simulation are the accelerations the car actually pulled, corner by corner. The domain modeled the pump suction as an outlet and the pressure-regulator return as an inlet, accounting for real fuel consumption over the lap. Because the input was real telemetry, the simulation output could be watched frame-by-frame against lap video to see exactly which corner or braking event caused which slosh pattern.

Any component whose safety margin depends on real dynamic loading — not just static geometry — benefits from being driven by real telemetry instead of idealized inputs. It turns a design assumption into a validated number.