2. introduction to automobile & body engineering.

An
Introduction to
Automobile & Body
Engineering
by
*Prof. Sumit S Dharmarao

Components of Automobile
Essential
units
Basic
Structure/
Running Gear
Power Plant
/Engine
Transmission
/Driving
System
Auxiliaries
Controls
Superstructur
e
2Prof. Sumit S. Dharmarao

1.Basic Structure / Running Gear:
contd
Basic
Structure
Frame
Suspension
System
Axle
Wheels &
tyre

2.Engine/ Power Plant:
Power required to move vehicle
P= m g µ V
Internal Combustion Engine (ICE) may be of SI or
CI type
• Turbine Engines
• Electrical Vehicles
• Hybrid Vehicles
• Solar Vehicles
contd

3.Transmission / Driving System:
• Functions:
1. connect and disconnect without shock
2. vary leverage between engine & drive line
3. reduce engine speed permanently as required
4. turn drive in 90 degrees
5. allow relative motion between engine and driving
wheel
• Clutch/Torque Converter GB Prop. Shaft
Uni. Jt. Diff. GB
contd

4.Control System:
1. Steering System
2. Braking System
5.Auxiliary / Electrical System:
1. Supply System
2. Starter
3. Ignition System
4. Auxiliary Devices
6.Super Structure
contd

General Layout of Automobile
Frame, Engine , Clutch, GB, Propeller Shaft, Diff. GB,
Rear Axle, Front Axle, Wheels

Types of Layout of
Automobiles
1. Front Engine Rear Wheel Drive: (FERWD)

2. Rear Engine Rear Wheel Drive: (RERWD)
contd

3. Front Engine Front Wheel Drive: (FEFWD)
contd

4. Four / All Wheel Drive: (4WD)
contd

5. Articulated Vehicle Layout: (AVL)
contd

Body / Superstructure
• Requirements of Automobile Body:
1. Strength
2. Stiffness
3. Torsional Stiffness
4. Space
5. Air Drag
6. Weather Protection
7. Light Weight
8. Corrosion Resistance
9. Safety

Types of Bodies of Automobiles
• Classification of Automobile:
• Classification of Vehicles in India:
1. Use
2. Capacity
3. Make & Model
4. Fuel Used
5. Body Style
6. Wheel
7.Drive
8.Transmission
1. HCV- 7.5 to 16.2
Tons
2. MCV- up to 7.5
Tons
3. Passenger cars-
seating capacity
up to 6 persons
Passenger Cars
UV, MUV,SUV

• Other Body Styles:
1.Saloon/Sedan
2.Hatchback
3.Coupe
4.Limousine
5.Fastback
6.Sports
7.Convertible
8.Cabrio/Semi Convertible
9.Coupe Convertible
10.Eastate/Station Wagon
11.SUV
12.Van
13.Truck
14.Articulaed Vehicle
15.Buses and Coach
contd
2W:
Standard/Street
Cruiser
Sport
Tourer
Scooters
Mopeds

Material for Automobile Body
• Wood Components joined with Steel Brackets
• Steels
• High Strength Steel [HSS]
• High Strength Low Alloy Steel [HSLA]
• Ultra Light Steel Auto Body [ULSAB]
• Aluminum And its Alloys

Chassis
• Chassis Consists of
Chassis
Engine
Radiator
Transmissio
n
System
Suspension
System
Wheels &
Tyres
Steering
System
Brakes
Fuels
controls
Auxiliary

• Framed & Frameless:
• Functions: 1. Support Component & Body
2. Withstand Static & Dynamic loads
• Loads on Frame:
contd
Chassis
Types
Conventional
control
Semi Fwd
Control
Full Fwd
Control
1.Weight of vehicle and passengers vertical bending of side members
2.due to road irregularity (bump) longitudinal torsion of lifted wheel
3.due to road camber, side wind, cornering force causes lateral bending of Side member
4.due to impact of road causes distortion of frame into parallelogram
5.Engine and Braking torque causes vertical bending of side members
6.Sudden impact loads during results in general collapse

• Frame construction:- Wheelbase, Overhang,
hole (bearings for axle), side bar, cross bar, body
support, bracket for mounting spring, X member to resist
twisting
contd

Types of frames
1. Ladder Frame:
Simplest, Oldest
2 symmetrical rails
Good flexing strength
Poor Torsional resistance 22Prof. Sumit S. Dharmarao

2. Tabular / Space frame:
3D design, good strength against forces coming from all
directions, tubes welded & forms complex structure, for
sport car where strong structure required
contd

3. Monocoque Chassis :
3D design, good strength against forces coming from all
directions, tubes welded & forms complex structure, for
sport car where strong structure required
contd

4. Backbone Chassis :
For lighter vehicle, strength against bending due to driving
torque
contd

5. ULSAB Chassis: Ultralight Steel Auto Body
(ULSAB)
contd
ULSAB AVC , targets using steel, high strength,
hydroforming

6. ASF Chassis :
For lighter vehicle, expensive
contd
Aluminum Space Frame (ASF)

7. CF Chassis :
Extreme stiff light weight, most expensive
contd

• Defects in frame: Alignment Fault due to accident
• Stainless Steel & aluminum
Frameless or Unitary Type

Aerodynamics
• Complex due to air flow, ground, geometrical shapes
involved. Affects both stability and fuel
consumption
• Drag Force (Fd)

Types of Drag Forces on Body
1. Form or Pressure Drag
2. Skin or Viscous or Friction Drag
3. Induced Drag
4. Excrescence Drag
5. Interference Drag

Drag Reduction Methods
• Streamlining automobile body
• Large eddy breakup devices
• Study of drag flow in airflow and water flow
• Automobile spoiler installed at rear & trail end

Different Forces and Moments
• Cross wind forces
• Pitching Moment
• Rolling Moment
• Yawing Moment

Ergonomics for driver &
Passenger Seat
• Correct driving position (W r t o steering
wheel, foot control other controls)
• Driver’s comfort & road safety
• Seat – adjustable seat
• Inclination of steering column
• Distance between seating position & floor of
vehicle

Prof. Sumit S. Dharmarao 35
Thank You
Sumit S Dharmarao
sumitdharmarao@gmail.com

2. introduction to automobile & body engineering.

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