vehicle body engineering- general information

1. VEHICLE BODY ENGINEERING
saeiss skip vbe G.
26/03/2016 Session 1-1.
GENERAL INFORMATION
cc ppt saeiss skip vbe 1.0. General information-
- Coomarasamy. C – Formerly Professor / Automobile Engineering
Bharath University

2. 1.0.0. VEHICLE BODY ENGINEERING-GENERAL INFORMATION
 OBJECTIVES:
 The main objective of this course is to impart knowledge in the
construction of vehicle, aerodynamic, concept, paneling of passenger
car body trim.
 At the end of the course the student will be well versed in the design and
construction of external body of the vehicles.
 OUTCOMES
Upon completion of the course, students will
 Know about different aspects of car body and bus body, types,
commercial vehicle.
 Role of various aerodynamic forces and moments, measuring
instruments
 Know about the material used in body building, tools used, body
repairs.

3. FUNCTION OF VEHICLE SYSTEMS
Vehicle System Function
Body • Provide durable attachment for other major systems
• Provide safe and pleasant seating environment for all
passengers
• Protect passengers from crashes
Chassis • Provide capability to steer the vehicle
• Provide capability to brake the vehicle safely
• Provide isolation between road and passengers
Powertrain • Provide capability to accelerate the vehicle by transferring
torque to wheels
• Provide capability to control vehicle speed
• Meet regulatory exhaust requirement
Climate Control • Maintain comfortable temperature distribution for passengers
• Provide windshield defrost capability
Electrical &
Electronics
• Provide power supply where needed
• Provide desirable entertainment system
• Provide functional censors and controls
1.0.0. VEHICLE BODY ENGINEERING-GENERAL INFORMATION

4. VEHICLE ATTRIBUTES
Vehicle
Attributes
Description
Cost Lowest production, assembly and distribution cost compared to
competitive vehicles
Weight Lowest curb weight compared to competitive vehicles in its weight class
Package Best use of the space to provide comfort and amenities to passengers
Safety 5* crash rating from the Federal Motor Vehicle Safety Standard (FMVSS)
Dynamics Best ride & handling performance compared to competitive vehicles
Durability Highest reliability and high mileage durability compared to competitive
vehicles
NVH Lowest noise, vibration and harshness compared to competitive vehicles
1.0.0. VEHICLE BODY ENGINEERING-GENERAL INFORMATION

5. 1.0.1. VEHICLE BODY DESIGN
Vehicle design
Engine & transmission Suspension Body
Body- shell structure
Body-equipment
Body- finish
Sections
Sub-groups Involves problems of
-Structural analysis
-Sheet metal forming
-Welding technique
Involves problems of
-paint and corrosion protection
-trim for internal finish
-sound insulation etc.,
Includes -door locks
-windows, seats
-heating and ventilation
-instruments etc.,
The design of the details in this group involves a knowledge of several
technologies from precision engineering for door locks to
thermodynamics for the heating system.
Body design must always be guided
by aesthetic considerations (or styling)
-this must be true for all the sub-groups

6. - reached a high standard in present vehicles
- have very similar performance from vehicle to vehicle
- competition has automatically eliminated inferior designs
- in the engine field – a very high standard in design and
quality of manufacture – being attained
- in the chassis design - a similar situation exists- perhaps to a lesser degree
Automatic transmission: additional expense
- but has as many supporters and opponents- opponents- based mainly
on the loss of interest in driving, rather than the cost
Suspension: air suspension – promised to bring about a greater advance
- but application to private cars- has slowed down- reasons difficult to
understand
- in coaches – more and more use – because of incomparably better ride
quality than traditional suspension units
It can be seen, therefore, that the body work is at present the main item
differentiating between competing vehicles.
The engine and chassis groups:
1.0.1. VEHICLE BODY DESIGN -IMPORTANCE

7. The total weight- to a large extent determined by the structural weight
- in private cars- body contributes 40-60% of the total weight
- in buses – 60-70 % of the total weight
The pay load- largely determined by the body weight, since the gross vehicle
weight is limited by the constant tyres and other components.
The reduction in body weight improves the capacity, fuel consumption and
other factors.
The aerodynamic characteristics of the body largely determine the
fuel consumption at high speed and the stability in cross winds.
Other body group factors:
- main customer appeal- e.g., well designed seats, dash board layout,
heating and ventilation, ease of entry, and finally most important
- styling of the whole vehicle.
- safety in collisions- is an important selling point.
-Finally the vehicle body determines the price of the vehicle- both
directly and indirectly.
-direct- 50 – 70 % of the total cost of the vehicle
- indirect- the expected life of the vehicle can also influence the price-
- body has the major influence.
1.0.1. VEHICLE BODY DESIGN -IMPORTANCE

8. 1.0.2. NECESSITY OF VEHICLE BODY
For the users, the vehicle body is one of the most important parts.
The requirements of the vehicle body are:
(i) structure and interior arrangement provide riding comfort and
convenience to the driver and passengers.
(ii) can give protection to the users from weather and reasonable safety
in case of accident.
(iii) should be free from distracting noises, when the vehicle is in
operation.
(iv) should remain free from body noises and squeaks over the periods
of its life.
(v) can give good appearance and a certain degree of beauty.
(vi) will give greater strength with light weight in order to reduce the
inertia forces and make possible rapid and effective braking and
acceleration.
(vii) should be aerodynamically designed with good fuel economy.
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9. The body engineer - must be familiar with-
 all problems of vehicle design and involved at all stages of design.
 installing standard catalogue items such as transmission and
suspension.
 legal requirements.
 the ergonomics of seating and controls.
 account problems of field of vision.
 over-all aerodynamics.
 preparation of perspective drawings and sketches and co operate
with the stylist.
 three dimensional geometry of curved surfaces, and be able to
supervise the construction of suitable models and mock ups.
 preparation of initial design drawings and carry out the structural
analysis on the body design.
 finally, comparison of the new design with the existing designs to
ensure that some advances has been made.
1.0.3. VEHICLE BODY ENGINEER- IMPORTANCE

10. Problems encountered by the body engineer
 Competition from other manufacturers
(leading to rapid fashion change)
 Aerodynamics
 Ever present problem of reducing cost
It is essential that the initial design should be correct in view of these very
complicated requirements
Detail design of the some of the body components may be undertaken by
specialized designers.
But, the final quality of the whole design depends on
initial body lay out and design
Engine and chassis units are easily replaceable, but serious damage
to the body means an end to its life.
1.0.3. VEHICLE BODY ENGINEER- IMPORTANCE

11. 1.0.4. PURPOSE OF BODY DESIGN
 The purpose of body design is to achieve the following:
 • Aesthetics: to provide a pleasing overall appearance, surface quality
and consistent details.
 • Structural function: to support the weight of the transported
passengers and load as well as the mechanical parts required for
vehicle propulsion, control and other system functions, so withstanding
mechanical stresses from multiple sources.
 • Ergonomy and roominess: to supply easy access and adequate
room for the driver, passengers and transported goods.
 Safety: to ensure integrity of passenger compartment in the event of a
crash, while absorbing the impact energy as well as to reduce injuries to
vulnerable road users (pedestrians, wheelers), in case of collision.
 • Aerodynamics: to minimize drag due to air impact; to control air flow
effects on tyre-road contact and vehicle stability.
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12.  • Insulation: to minimize noise, vibration and thermal transmission,
generated by body walls, by lack of sealing between compartment and
movable parts and by thermal radiation from the surfaces of passengers
compartment.
 • Visibility: to provide the highest possible day and night visibility on the
environment and to host the lighting devices in the most effective way.
Moreover, the body must satisfy a series of pre-requisites:
high reliability (to maintain design functions vehicle life along),
low cost (to minimize production investment, process and material
cost),
high material recyclability (by rapid disassembling and straightforward
division of heterogeneous materials).
These functions ere required by the completely assembled body and
are achieved through the individual contribution of body
components and several body systems.
For some of the functions listed above, a number of different
configurations of the underbody can be identified.
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1.0.4. PURPOSE OF BODY DESIGN

13. Automobiles can be classified from various point of view of
considerations like ;
Use : Motorcycle, car, Bus, …
Capacity : HTV,LTV, …
Make : Maruti, Honda, Bajaj, …
Model : Zen,
Fuel : Petrol, Diesel, CNG, …
Wheels : Two, three, four, ...
Drive : Left hand drive, Front
wheel drive, ...
1.0.5. GENERAL CLASSIFICATION OF CAR

14. Cars may be classified by a number of different criteria and objectives.
Governments and private organizations have developed car
classification schemes that are used for innumerable purposes
including regulation, description and categorization, among others.
However, comprehensive classification is elusive- difficult to find,
catch, or achieve -because a vehicle may fit into multiple categories,
or not completely satisfy the requirements for any.
The commonly used classifications
1. The European New Car Assessment Programme (Euro NCAP)
2. ACRISS (the Association of Car Rental Industry Systems
Standards)
3. Highway Loss Data Institute (HLDI)
4. The National Highway Traffic Safety Administration (NHTSA)
5. Federal Highway Administration
6. United States Environmental Protection Agency (US EPA)
7. By the Canadian EPA Canadian National Collision Database
(NCDB) system
8. SIAM (Society of Indian Automobile Manufacturers)
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1.0.5. CLASSIFICATION OF CAR

15. 1.0.5.1. THE EUROPEAN
NEW CAR ASSESSMENT PROGRAMME (EURO NCAP)
 The European New Car Assessment Programme (Euro NCAP)
is a European car safety performance assessment programme
based in Brussels (Belgium) and founded in 1997 by the
Transport Research Laboratory for the UK Department for Transport
and backed by several European governments, as well as by the
European Union.
EURO NCAP FRONTAL TEST
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an offset deformable barrier

16. EURO NCAP SIDE IMPACT
1.0.5.1.THE EUROPEAN NEW CAR
ASSESSMENT PROGRAMME (EURO NCAP)
EURO NCAP PEDESTRIAN TEST
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EURO NCAP SIDE IMPACT, POLE TEST
50 km/h (31 mph)
32 km/h (20 mph)
40 km/h (25 mph)

17. 1.0.5.2. ACRISS (THE ASSOCIATION OF CAR RENTAL
INDUSTRY SYSTEMS STANDARDS)
 The ACRISS Car Classification Code developed and maintained by
ACRISS (the Association of Car Rental Industry Systems
Standards)and is designed to enable customers and travel professionals
to make an informed choice when booking car rental in Europe, Middle
East and Africa.
 ACRISS Members include Avis, Budget, Alamo, Europcar, Hertz and
National. Others also subscribe to the codes e.g.Atlas Choice and ASAP
Ventures.Many other Car Rental companies also utilise this
car coding standard.
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18.  ACRISS Members utilise an industry standard vehicle matrix to define
car models ensuring a like to like comparison of vehicles. Car codes are
created by assigning one character from each column and combining
them into a four-character car code:
 1st character denotes the vehicle category –
based on size, cost, power and luxury factor
 2nd character defines the vehicle type – chassis type
(van, SUV, wagon, convertible….)
 3rd character defines the transmission and drive –
automatic / manual & 2WD / 4WD / AWD
 4th character defines the fuel type
(petrol / diesel / hybrid…) and whether air conditioned
(e.g. : CCMN = Compact Car – 2/4 Door – Manual Transmission – Non
air-conditioned)
1.0.5.2. ACRISS (THE ASSOCIATION OF CAR RENTAL
INDUSTRY SYSTEMS STANDARDS)

19. 1.0.5.3. HIGHWAY LOSS DATA INSTITUTE (HLDI)
HLDI classification Definition
Sports
Those cars with significant high performance
features
Luxury Higher-end cars that are not classified as sports
Large
Length more than 495.3 cm (195 in) and wheelbase
more than 279.4 cm (110 in)
Midsize
Length 457.3–495.3 cm (180–195 in) and wheelbase
266.8–279.4 cm (105–110 in)
Small
Length less than 457.2 cm (180 in) and wheelbase
less than 266.7 cm (105 in)
For research into safety, the Highway Loss Data Institute takes into
account a combination of both vehicle size and other vehicle features
with all passenger cars that do not fit the definition of either "sports" or
"luxury", are classified on the basis of both vehicle length and
wheelbase
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20. 1.0.5.4. THE NATIONAL HIGHWAY TRAFFIC
SAFETY ADMINISTRATION (NHTSA)
NHTSA classification Code Curb weight
Passenger cars: mini PC/Mi 1,500–1,999 lb (680–907 kg)
Passenger cars: light PC/L 2,000–2,499 lb (907–1,134 kg)
Passenger cars: compact PC/C 2,500–2,999 lb (1,134–1,360 kg)
Passenger cars: medium PC/Me 3,000–3,499 lb (1,361–1,587 kg)
Passenger cars: heavy PC/H 3,500 lb (1,588 kg) and over
Sport utility vehicles SUV -
Pickup trucks PU -
Vans VAN -
The National Highway Traffic Safety Administration (NHTSA)
separates vehicles into classes by the curb weight of the vehicle with
standard equipment including the maximum capacity of
fuel, oil, coolant, and air conditioning, if so equipped).
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21. 1.0.5.5. FEDERAL HIGHWAY ADMINISTRATION
 Another vehicle classification scheme has been developed by the
U.S. Federal Highway Administration for
automatically calculating road use tolls.
 There are two broad categories depending on whether the vehicle
carries passengers or commodities,
with non-passenger vehicles further subdivided by
number of axles and number of units,
including both
power and
trailer units.
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22. 1.0.5.6. UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY (US EPA)
EPA car class Total passenger and cargo volume (cu. ft.)
Two-seaters Any (designed to seat only two adults)
Minicompact Less than 85 cu ft (2,407 l)
Subcompact 85–99 cu ft (2,407–2,803 l)
Compact 100–109 cu ft (2,832–3,087 l)
Mid-size 110–119 cu ft (3,115–3,370 l)
Large 120 cu ft (3,398 l) or more
Small station wagons Less than 130 cu ft (3,681 l)
Mid-size station wagons 130–159 cu ft (3,681–4,502 l)
Large station wagons 160 cu ft (4,531 l) or more
The United States Environmental Protection Agency(US EPA) has
another set of classification guidelines that are based on the vehicle's total
interior passenger and cargo space.
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23. 1.0.5.7. BY THE CANADIAN EPA CANADIAN NATIONAL
COLLISION DATABASE (NCDB) SYSTEM
 A similar set of classes is used by the Canadian EPA.
 The Canadian National Collision Database (NCDB) system defines
"passenger car" as a unique class, but also identifies two other
categories involving passenger vehicles—
the "passenger van" and
"light utility vehicle"—
and these categories are inconsistently handled across the country with
the boundaries between the vehicles increasingly blurred.
 In Australia, the Federal Chamber of Automotive Industries
publishes its own classifications.
Another standard for road vehicles of all types that is used
internationally (except for Australia, India, and the U.S.), is ISO
3833-1977.
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24. 1.0.5.8. SIAM
(SOCIETY OF INDIAN AUTOMOBILE MANUFACTURERS)
 Classification of car Segments and types is done on the basis of the
length of the vehicle (Passenger car segment)

S.N
o
Segment Type Length Cars
1 A1 Mini Up to 3400mm M800, Nano
2 A2 Compact 3401 to
4000mm
Alto, wagon r, Zen,i10,A-
star,Swift,i20,palio,indica etc
3 A3 Midsize 4001 to
4500mm
City, Sx4, Dzire, Logan, Accent, Fiesta,
Verna etc
4 A4 Executive 4501 to
4700mm
Corolla, civic, C class, Optra, Octavia etc
5 A5 Premium 4701 to
5000mm
Camry, E class, Accord, Sonata, Laura,
Superb etc
6 A6 Luxury Above 5000mm Mercedes S class, 5 series etc
7 B1 Van – Omni Versa, Magic etc
8 B2 MUV/MPV Innova, Tavera, Sumo etc
9 SUV CRV Vitara etc

25. 1.0.5.8. SIAM
(SOCIETY OF INDIAN AUTOMOBILE MANUFACTURERS)
1 ONE
BOX
VAN/MPV It means Engine area, Passenger area &
luggage area all in one box. There wont be
separate compartment
eg. Omni, Ace Magic,
Versa
2 TWO
BOX
HATCHBACK – It means Engine are has a separate cabin
while Passenger area and luggage area are
together
eg. M800, Alto, Santro,
i10, A*, Swift etc.
3 THREE
BOX
SEDAN/SALOON/
NOTCHBACK
It means Engine area, Passenger area &
luggage area all are having different cabin
eg. SX4, City, Fiesta,
Dzire, Ambassador,
Indigo CS etc
4 ESTATE/STATION
WAGON
Its nothing but sedan whose roof is
extended till the rear to create more boot
space
eg. Indigo Marina,
Octavia Combi, etc.
5 SUV (Sports Utility
Vehicle)
These vehicles have large tyres, higher
seating, higher ground clearance. The
engine area is separate, but the passenger
& luggage area are enclosed together. Most
of these vehicles are equipped with either 4
wheel drive system or has the option for
that.
eg. CRV, SAFARI,
GRAND VITARA,
PAJERO etc
6 SEMI NOTCHBACK Its a sedan whose boot door can be opened
like a hatchback (wagon r, swift), where the
rear wind shield too opens along with the
boot door. Unlike sedan whose rear wind
shield is always fixed
Skoda Octavia, Accent
Viva.
Classification of Cars based on body Shape

26. 1.0.6. OTHER CAR CLASSIFICATION TERMS
 Bakkie - A generic South African term for light pickup truck.[citation needed]
 Buggy - A Buggy is an automobile with wheels that project beyond the
vehicle body.
 Cabrio coach or Semi-convertible - A form of car roof, where a
retractable textile cover amounts to a large sunroof.
 Corniche - Sometimes used to describe a luxury sedan or town car.
Actually a trade mark of Rolls-Royce.
 El Camino - The 1959 Chevrolet El Camino was a half-car (front) and
half-truck (back) with low walls surrounding the bed. El Camino is used
by some Americans and Canadians as a generic term for any passenger
car with an integral cargo bed.
 Estate car - British name for a station wagon.
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27.  Fastback - A design where the roof slopes at a smooth angle to the tail
of the car, but the rear window does not open as a separate "door".
 Drop Head Coupe - Generally a European term referring to a 2 door, 4
place automobile with a retractable canvas / cloth top with both a
padded headliner and rollup windows (as opposed to side curtains).
 Flower Car - in US, similar to ute in Australia, i.e. generic for Chevy El
Camino, Ford Ranchero, GMC Sprint/Diablo, etc.;
 Hearse: A converted car to transport the deceased.
 Kammback - Originally, a car with a tapered rear that cuts off abruptly.
 Landaulet - A limousine with the passenger section covered by a
convertible top.
 Liftback - A broad marketing term for a hatchback, which incorporates a
shared passenger and cargo volume, with rearmost accessibility via a
top-hinged liftgate.
 Limousine - By definition, a chauffeur-driven car with a (normally glass-
windowed) division between the front seats and the rear. In German, the
term simply means a sedan.
1.0.6. OTHER CAR CLASSIFICATION TERMS
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28.  Microvan - Term for a boxy wagon-type of car that is smaller than a
conventional minivan.
 Notchback - A configuration where the third box of a three-box styling
configuration is less pronounced — especially where the rear deck (third
box) is short or where the rear window is upright.
 Phaeton - A Phaeton is a style of open car or carriage without proper
weather protection for passengers.
 Ragtop - Originally an open car like a roadster, but with a soft top (cloth
top) that can be raised or lowered. Unlike a convertible, it had no roll-up
side windows.Now often used as slang for a convertible.
 Sedan delivery - North American term for a vehicle similar to a wagon
but without side windows, similar to a panel truck but with two doors
(one on each side), and one or two rear doors.
 Spyder (or Spider) - Similar to a roadster but originally with less weather
protection.Nowadays it simply means a convertible.
1.0.6. OTHER CAR CLASSIFICATION TERMS
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29.  Shooting-brake - Initially a vehicle used to carry shooting parties with
their equipment and game; later used to describe custom-built wagons
by high-end coachbuilders, subsequently synonymous with ;Sports
Wagon: A term used by a number of manufacturers in the North
American market for their station wagon models.
 Targa top - A semi-convertible style used on some sports cars,
featuring a fully removable hard top roof panel which leaves the A and B
pillars in place on the car body.
 Town car (US) - Essentially the inverse of the landaulet, a historical
body style in which the front seats were open and the rear compartment
closed, normally with a removable top to cover the front chauffeur's
compartment. In Europe the style is also known as Sedanca de Ville,
often shortened to Sedanca or de Ville. Note that the modern Lincoln
Town Car derives its name, but nothing else, from this style.
 Ute - Australian/New Zealand English term for the vehicles with a cargo
bed at the rear.
 Wagon delivery - North American term (mainly U.S. and Canada).
Similar to a sedan delivery, with four doors.
1.0.6. OTHER CAR CLASSIFICATION TERMS
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30.  Non-English terms
 Some non-English language terms are familiar from their use on
imported vehicles in English-speaking nations even though the terms
have not been adopted into English.
 Barchetta - Italian term for a roadster. The name means, roughly, "small
boat".
 Berlina -Italian term for a sedan.
 Berline - French term for a sedan.
 Berlinetta - Italian term for a sport coupé.
 Break - French term for a station wagon.
 Camioneta - Brazilian Portuguese term for a station wagon (specially in
the state of Rio de Janeiro).
 Carrinha - Portuguese term for a station wagon. Not used in Brazilian
Portuguese.
 Espada - Portuguese nickname for a limousine (the same word for
Sword - long piece of metal). Not used in Brazilian Portuguese.
 Furgoneta - Spanish and Polish term for a van, in the latter language
almost always used in its diminutive form furgonetka.
1.0.6. OTHER CAR CLASSIFICATION TERMS
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31.  Furgão - Portuguese alternative term (less used) for a van. Used in
Brazilian Portuguese, most often for vans but sometimes for panel van
variants of passenger cars.
 Kombi - is a German abbreviation of "Kombinationswagen"
(Combination Car) and it is German name for station wagon. Since
Germany is a major producer of cars for many European countries, the
term Kombi in this meaning is also used in Swedish, Czech, Slovak,
Polish, Slovenian, Serbian, Bosnian, Croatian, Hungarian, Spanish,
Portuguese, Bulgarian. In Afrikaans and in Australia, Kombi is also used
to refer to a Volkswagen Microbus. In Brazil the word specifically refers
to the VW Microbus.
 Perua - Brazilian Portuguese term either designating a van (especially
as spoken in the city of São Paulo) or a station wagon (in the city of Rio
de Janeiro).
 Turismo - Spanish term for a sedan. Literally means tourism, used
mostly in Latin American countries.
1.0.6. OTHER CAR CLASSIFICATION TERMS
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32. REFERENCES
1. Powloski, J., Vehicle Body Engineering, Business Books Ltd., 1998.
2. Dieler Anselm., The passenger car body, SAE International, 2000.
3. John Fenton, “ Vehicle Body Layout and Analysis”, Mechanical
Engineering Publications Ltd., London 1980.
4. Qadeer Siddiqui M A ., Vehicle Body Engineering and Safety.
5. Selvakumar, V., Vehicle Body Engineering, Shri Amman Publications.
Devanapatti. 2002.
6. Kumaresan. M., Vehicle Body Engineering. AMK Publishers. Madurai.
2005.
7. http://www.motortrend.in/autonews.htm#ixzz2Y5A2ACR3
8. Google webs and images.