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I'm pretty sure Mythbusters tested this ...
The first mythbusters one they did on it was revisited. They tested all sorts of things, including different car types/shapes and driving situations. Hence, in general anything under 60km/hr use windows, any higher use air-con. At 60km/hr, the difference is so small you might as well AC as it is more comfortable.Windows down vs aircon
http://dsc.discovery.com/tv-shows/mythbusters/mythbusters-database/ac-vs-open-windows.htm
But then there's Snopes: http://msgboard.snopes.com/cgi-bin/ultimatebb.cgi?ubb=get_topic;f=20;t=000565;p=0
On freeway out of the city it's windows down in but urban areas windows up and ac on. Too much risk driving with the windows down.
Windows down to get rid of the immediate heat and hot air, and when it's more balanced aircon time.
I'm pretty sure Mythbusters tested this ...