2 - Vehicle Body1 PDF

8/20/19
Automobile Engineering
Vehicle Body
Dr. Devender Kumar, AP, MED, TIET, Patiala
Vehicle Body Design
SEDAN
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Sedan/Saloon
• A sedan or saloon is a passenger car in a three-box
configuration with A, B & C-pillars and principal volumes
articulated in separate compartments for engine, passenger
and cargo.
• The passenger compartment features two rows of seats

and adequate passenger space in the rear compartment for
adult passengers.
• The cargo compartment is typically in the rear.
• It is one of the most common car body styles.

Hatchback
5 Door
3 Door
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Hatchback
• It has 5 or 3 doors.
• 2 front, 2 back and one for the boot.
• This design is commonly found on small compact

cars .
Pickup
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Pickup
• A pickup truck normally has a separate cab and

bed.
• Most pickup trucks use a front-engine, rear-

wheel drive setup.
• Some are four-wheel drive.
SUV
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SUV
• An SUV, or sport utility vehicle, has two wheel drive or

four-wheel drive mode and room for multiple
passengers.
• This all-weather vehicle generally sits higher than

passenger cars for increased ground clearance on
rough terrain.
• Often classified as an off-road vehicle, the SUV is

ideal for driving through snow, rough terrain and mud.
Station Wagon/ Estate
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Station Wagon/ Estate
• Also known as a estate , shooting-brake, or sports wagon,

the estate car has the roof extended to the rear to enlarge
the internal capacity.
• This is a 2-box style car with 4 pillars.
• You can imagine it to be a sedan with the roof extended

completely up to the rear end.
• A tailgate (door at the rear) enables bulky or long objects

to be loaded easily.
Van
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Van
• The van body design has a tall roof and a totally

enclosed large cargo or passenger area.
• Vans can seat from two to twelve passengers,

depending on size and design.
• Basically, there are two sizes of vans: mini- and full-

size.
• The most common are mini-vans
Convertible
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Convertible
• A convertible uses a retractable canvas roof with
a steel tube framework. Vehicle layout 11
• The top folds down into an

Bodywork
area behind the seat.
Most modern body styles have to be designed to
meet stringent build and safety requirements. Body
• Some convertibles use a construction
The main purpose of the bodywork is to provide
accommodation for the driver and passengers,
removable hardtop.
is designed to include safety crumple
along with suitable protection against wind, weather zones. These are areas specially designed to absorb
• Some
and collision. newer
The degree of comfort vehicles
provided will have gone
impact and protect back
occupants to Allthe
in a collision. vehicles
have to pass a number of crash tests to be certificated
use of retractable hardtops.
naturally depend upon the type of car and its cost.
prior to customer ownership. Many of today’s vehicles
The majority of mass-produced cars have a pressed- use special high-strength steels, such as boron steel, to
steel •body,
A hardtop doesaluminium
although lightweight not have is a centre
increase pillar
the strength to support
of the passenger compartment
increasingly being used as a viable alternative. Where or, as it is often called, the ‘safety cell’. When repairing
productionthe roof,
is small scale, so
it is the roof
usual to mustthese
construct betypes reinforced to important
of vehicles, it is very provide to make
the body by either hand-working aluminium alloy
enough strength.
into shape, moulding glass-reinforced plastics (GRP/
sure that you understand about the different metals
used as they have different properties and require
fibreglass) or using composite materials, such as carbon various different methods of joining.
• A hardtop is available in both two- and four-door
fibre. As body design technology continues to progress,
manufacturers are keen to produce their vehicles Body styles
versions.
with a sleek, aerodynamic, eye-catching look to entice Saloon
customers to purchase. As we now live in aDr.world where
Devender Kumar, AP, Saloons
MED, TIET, are
Patiala
fully enclosed two- or four-door cars for
global demand on resources is great, manufacturers
four or more people. The common shape of body
have to consider using many reusable materials when
shell is based on three ‘boxes’; the front box forms the
designing each new model range. Materials such as
engine compartment, the centre box the passenger
aluminium and magnesium are now commonly used
capsule and the rear box a storage space, called a
in body construction, and advanced plastic compound
boot (trunk), for the luggage. The three boxes are
materials are used in areas such as bumpers, sill panels
blended together to give a pleasing appearance and
and wheel arches. Depending on the body materials
are shaped to enable the car to move through the air
used, surfaces must be treated and painted. Primarily
with the minimum drag.
this is to give protection against rust or other corrosion,
and secondly to improve the appearance. External trim, For safety purposes, the passenger capsule must be
made of stainless steel, chromium-plated brass, plastics suitably strengthened to keep its shape following
or rubber, embellishes the body and appeals to the eye any collision with another object. Extra safety during
by providing a contrast with the plain coloured surface. front or rear impact can be obtained by designing
Figure 1.16 shows some of the body styles used for cars. the front and rear regions of the car to fold up in
saloon convertible
coupé estate
people carrier hatchback

Figure 1.16 Some of the body styles used for cars
8
popular and usually have four-wheel drive to enable
operation in extreme or off-road conditions. Like
light commercial vehicles, they may have either a 8/20/19
separate chassis or monocoque designs. Engines are
Figure 1.20 Car-derived
usually light commercial
from the passenger vehiclebut
vehicle range (van)
in most
cases have modifications to enable them to operate
in extreme conditions, such as wading through water
Manufacturers normally offer a number of different
or operating on steep inclines. These vehicles often
d light commercial vehicle
body shapes and sizes to suit the customer’s needs.
have sophisticated mechanical and electrical systems
When a vehicle is required for the transportation
to improve traction. This is discussed in more detail
of bulky
on pageequipment,
496. for example, materials carried
by builders and decorators, an open body is often
preferred. A light vehicle having this partly enclosed
body is called a pick-up (Figure 1.21).
ment panel
Small vans and pick-ups have two seats for the
driver and one passenger and a standard of comfort SUV
to the advancement comparable to the base model of the car from which
nstrument panels and the vehicles were derived.
itally controlled. The
accurate information
rcial vehicle with
ndertaken. twin wheels for
Information Figure 1.25 Latest type of four-wheel drive vehicle from
Land Rover – Range Rover Evoque
r by means of warning
system. Some driving Pick-up Truck
cally or are voice-
n in phone and audio
s.
Figure 1.31 Single-decker bu
m commercial
Figure 1.21 Example of pick-up type vehicle
icles are used for the

ht goods, usually over Most vans have a load-carrying capacity of about
e the type of vehicle 0.5 tonnes. Since low-cost operation is an essential
ry their equipment or factor, these vehicles are often fitted with a diesel-
cal deliveries to their (compression-ignition) type engine, although many
are now fitted with electrical or hybrid power.
engine
Vehicle layout 17
Classification of Commercial Vehicles Figure 1.32 Single-decker bu
Figure 1.29 Articulated vehicle without trailer its side
Figure 1.31 Single-decker bus with front entrance
final drum
engine gearbox
Figure 1.32 Single-decker bus chassis with engine laid on
Tractor
Figure 1.29 Articulated vehicle without trailer
Figure
Tractor & Articulated Trailer
its side
1.30 Articulated vehicle with trailer Figure 1.33 Double-decker b
Buses (omnibuses) A double-decker bus ca

passengers is shown in Fi
Buses are designed to transport large numbers of
and Use Regulations stip
passengers. Up to about 40 passengers may be carried
the vehicle and a minim
onKumar,
Dr. Devender a single
AP, MED,flTIET,
oorPatiala
or deck. Figure 1.31 shows a single-
upper and lower decks. T
decker bus, which has its entrance to the front where
the lower deck must be f
the driver can see passengers boarding or alighting
least along the central gan
from the vehicle. On some earlier buses no doors
permit this, the final-driv
were fitted to allow passengers quick access on or
of the rear axle but are mo
Figure 1.30 Articulated vehicle with trailer offFigure
the 1.33
bus.Double-decker
Now, with busimproved safety requirements,
with rear entrance
gangway does not have t
all buses have doors to ensure the passengers get
the axle casing.
Buses (omnibuses) on Aand off the bus
double-decker in a safe,
bus capable controlled
of seating about 60manner. The
passengers is shown in Figure 1.33. The Construction
Buses are designed to transport large numbers of doors are operated by the driver or conductor to In early bus designs th
forward directly9 over th
and Use Regulations stipulate a maximum height for
passengers. Up to about 40 passengers may be carried
prevent passengers
the vehicle and a minimum getting
ceilingon or off
height for while
both the bus is
on a single floor or deck. Figure 1.31 shows a single-
decker bus, which has its entrance to the front where moving.
upper and In order
lower to
decks.make room
This means for
that thethe
floorfront
of entrance, to the nearside to allow
the lower deck must be fairly close to the ground, at
8/20/19
4X2
Rigid Body Truck
d structure
and structure
8X4
Tandem Axle
s mainly
rates ononlight
mainly light
Rigid Body Truck
eavier vehicles
heavier vehiclesisis
oses.
s.
are generally
generally referred
referred
hicles. A medium-sized
es. A medium-sized Dr. Devender Kumar, AP, MED, TIET, Patiala
rised mass of between
d mass of between
large goods vehicle
rge goods vehicle
haul goods where the
goods where the
ceeds 7.5 tonnes. There
ds
eight7.5 for
tonnes.
large There
HGVs of
htsixfor large HGVs of Figure 1.26 A three-axle six-wheel HGV
axles.
Figure 1.26 A three-axle six-wheel HGV
axles.
on of goods a truck is
in goods
variousashapes Alternative
of truck and
is
needed to carry the arrangement
various shapes and
this chassis was only engine using twin
eded to carry the final
no special effort was
engine
gearbox drum front axles
s chassis
ch was onlyof
usually consisted Figure 1.27 Alternative arrangement finaltwin front axles
special effort was gearbox using
drum
mbers joined by several
usually consisted
en supported of
the main Figure 1.27 Alternative arrangement using twin front axles
rswell
joined by several
as the platform,
upported
body, the
and the main
driver sat
le. Today’s
ell as the trucks often
platform,
y,centre of gravity
and the driverdown
sat Eight wheeler
e and aerodynamic.
Today’s trucks often using twin
ntre of gravity down
ression-ignition, diesel front axles and
d aerodynamic.
and the driver sits high twin rear axles
eat for a passenger at
sion-ignition, diesel final
e of the space from the Dr. Devender Kumar, AP, MED, TIET,drum
Patiala
thecarrying
driver sits high gearbox
or the load. Figure 1.28 Eight wheeler using twin front axles and twin
for a passenger at
ar rear axles final
thewheels
spaceeither have
from the drum
or special wide-section gearbox
driven. Eight-wheelers have two front axles (steered
carrying the load. Figure 1.28driven)
Eight wheeler using
g a certain total loaded but not and two reartwin front
axles axles and
(driven but twin
not
wheels either
six wheels haveon
carried rear axles
steered) as shown in Figure 1.28.
rpecial
vehicles are required
wide-section driven.
Trucks Eight-wheelers
are allowed to have
tow atwo frontonaxles
trailer (steered
which an
ach of four
certain axles.
total These
loaded but not driven) and two rear axles (driven buta not
additional load can be carried. There is, in addition,
10
wn in the Construction
wheels carried on steered) as shown
type of vehicle in Figure
that consists of1.28.
two parts: a four- or six-
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Automobile Body Parts
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Major Body Sections
Automobile
Front section
Centre section
Rear section

Major Body Sections
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Front section
• The front section, also called the nose section,
includes everything between the front bumper and
the firewall.
− The bumper,
− grille,
− frame rails,
− front suspension parts,
− and the engine
are a few of the items included in the front section
of a vehicle.
Centre section
• The vehicle’s center section, or midsection,
typically includes the body parts that form the
passenger compartment.
– floor pan,
– roof panel,
– cowl,
– doors,
– door pillars,
– glass,
– and related parts.
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Centre section
• The center section is nicknamed the “greenhouse”

because it is surrounded by glass.
Rear section
• The rear section (the tail section, or rear clip)
commonly consists of the rear
– quarter panels,
– trunk or rear floor pan,
– rear frame rails,
– trunk or deck lid,
– rear bumper,
– and related parts.
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Frame
Frame
• The frame in a vehicle may be compared to the skeleton in
the human body.
• Without the skeleton, a human body would not be able to

stand erect.
• Likewise, if a vehicle did not have a frame, it could not

support its own weight or the weight of its passenger or
cargo load.
• The frame is the strong metal structure that provides a

mounting place for the other parts of the vehicle.
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Frame
• The frame holds the
– engine,
– transmission,
– suspension,
– and other assemblies in position.
• Frames are usually made of

– steel or aluminium
– and sometimes composite materials.
• The frame can be

– separate from the body
– or integrated into the body shell, as in the case of unibody design.
Functions of Frame
• The frame holds the engine, transmission, suspension, and
other assemblies in position.
• Allows the vehicle to support its total weight.
• Allows the vehicle to absorb stress when driving on rough
road surfaces.
• Enables the vehicle to absorb torque from the engine and
drive train.
• The frame, together with the front and rear suspension
systems, must position the wheels properly to minimize tire
tread wear and provide accurate steering control.
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Frame Construction
• Frame construction usually consists of channel shaped
steel beams welded and/or fastened together.
• The frame of a vehicle supports all the “running gear” of the

vehicle, including the engine, transmission, rear axle
assembly (if rear-wheel drive), and all suspension
components.
• This frame construction, referred to as full frame, is so

complete that most vehicles can usually be driven without
the body.
• Most trucks and larger rear-wheel-drive cars use a full

frame.
Frame Construction
• Vehicle frame construction may contain three types of steel
members: channel(partial box) frame, complete box frame,
or tubular frame.
• On modern vehicles, most frames include all three types.
Channel Square Tube Circular Section

or Section
C Section
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Chassis Operating Conditions

1. Vertical Bending
2. Longitudinal Torsion
3. Lateral Bending
4. Horizontal Lozenging
Dr. Devender Kumar, AP, MED,

TIET, Patiala

TIET, Patiala
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Section Strength

TIET, Patiala
Auto Body Construction

Frames
Body-over-frame
Body as frame (unibody)
Space Frame
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Body-over-frame Construction
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• The body over frame design is commonly used to describe
those vehicles that have a separate frame and body, both of
which are independent of each other.
• The vehicle may have either a full or partial frame.
• On the full frame, the rails span the entire length of the
vehicle, extending from the front completely to the rear end.
• Partial frame or stub frame is a shortened section under

the front of the vehicle only.
• The frame is essentially the vehicle's backbone and is
responsible for the majority of the body's strength
characteristics and support.
• The body, engine, and drivetrain, as well as the steering

and suspension parts, all attached to flanges that are
welded or riveted to the frame.
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Frames
Body-over-frame
Body-over-frame
Body as frame (unibody)

Ladder Frame Design
Space Frame The Perimeter Frame
Monocoque X-frame (or backbone frame)
(1) Ladder Frame Design
• The ladder frame gets its name from its likeness

to a conventional ladder.
• It is typically used for larger and heavier

applications such as trucks, passenger and cargo
vans, and fourwheel-drive vehicles where added
strength is required.
• Two relatively straight side rails that run parallel

to the body—with several cross-members welded
or riveted at strategic locations—are generally
employed to complete the assembly.
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• The side rails are typically a three-sided “U” channel design

except in areas where additional strength is required, such as
under the engine and transmission mounting locations, where
they may be a closed box design.
• The wheels and much of the steering mechanism—such as the

spindle, control arms, steering arms, and so on—nearly always
extend to the outside of the frame side rails.
• The cross-members are used to reinforce the frame and for

mounting most of the body, steering, and suspension parts.
• They are strategically placed in the areas where mounting the cab
and box is most easily accomplished, to simplify removal and
installation, and to maximize the strength of each.
• They are also used to attach and support the steering and
suspension, the transmission, and other drivetrain parts.
• The area immediately under the engine is generally quite heavily

reinforced with additional supports and metal thickness to
accommodate the additional weight.
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• Vehicles using the ladder frame typically have a higher center of
gravity since the cab and the remaining body components are
attached above the frame.
• This gives the vehicle added height, making it prone to tipping

over more easily.
• At the same time, the added height results in additional road

clearance, making it more suitable for use in rough and irregular
terrains.
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(2) The perimeter frame
(2) The perimeter frame
• As vehicle designs improved, the early ladder frames were
modified and improved to absorb impact energy more
efficiently.
• The perimeter frame is similar in construction to the ladder
frame.
• The most significant differences are the
– drop center design,
– the kickup areas, and
– the widened center section used to protect and reinforce the
perimeter of the vehicle's passenger compartment.
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(3) Backbone frame
(3) Backbone frame
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(3) Backbone frame
Backbone tube chassis is a type of an automobile construction

chassis that is similar to the body-on-frame design. Instead of a
two-dimensional ladder type structure, it consists of a strong
tubular backbone (usually rectangular in cross section) that
connects the front and rear suspension attachment areas. A body
is then placed on this structure.
(3) Backbone frame
• Backbone chassis is very simple: a strong tubular backbone

(usually in rectangular section) connects the front and rear axle
and provides nearly all the mechanical strength.
• Inside which there is space for the drive shaft in case of front-
engine, rear-wheel drive layout like the Elan.
• The whole drivetrain, engine and suspensions are connected to

both ends of the backbone.
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(3) Backbone frame
• It's strong enough for smaller sports cars but not up to the job for
high-end ones.
• The backbone does not provide protection against side impact or
off-set crash.
• Easy to be made by hand thus cheap for low-volume production.
• Simple structure benefit cost.
• It provides space-saving.
Frames
Frames
Body-over-frame
Body as frame (Unibody)
Space Frame
Monocoque
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Unibody Construction
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• Also called united body / unitized construction.
• Most front-wheel-drive cars have a this type of construction.
• In this body design, the frame and body are combined as one
unit, and the external frame assembly is eliminated.
• Sheet metal body panels are welded together to form the body
and frame.
• The strength and rigidity of the body is achieved by body design

rather than by having a heavy steel frame to support the body.
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• All the members of a unitized body are load-carrying
components.
• The floor pan, roof, inner aprons, quarter panels, pillars,

and rocker panels are integrally joined to form a unitized
body .
• Most unitized bodies have bolt-on partial frames at the front

and rear of the vehicle.
Unibody having a bolt-on partial/subframe

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• Some of the components in a unitized body are made from

high-strength steels (HSS) to provide additional
protection in a collision.
• Ultra-HSS may be used in such unitized body components

as door beams and bumper reinforcements.
• The unitized body has a complex design that spreads

collision forces throughout the body to help protect the
vehicle occupants.
Frame Construction
Frames
Body-over-frame
Body as frame or
unibody)
Space Frame
Monocoque
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Space Frame
• A close relative of the unibody vehicle is the space frame

design.
• The undercarriage on this vehicle is very similar to that of

the unibody in that the steering and suspension parts are
attached to the body.
• The principal difference between the space frame and the

unibody is the main structure: It is a self-contained, crash-
worthy frame made of lightweight high strength steel with
composition panels fastened to it.
Space Frame
• Unlike the unibody, it is not dependent upon the exterior

panels for strength and rigidity and will perform the same
with or without the exterior panels attached.
• Sheet molded compound (SMC) exterior panels are

attached by applying adhesive bonding, attaching them with
fasteners, or using a combination of both.
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Space Frame
Monocoque
• Monocoque is a construction technique that supports structural
load by using an object's exterior, as opposed to using an internal
frame or truss that is then covered with a non-load-bearing skin or
coachwork.
• Monocoque construction was pioneered in aircraft.
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Modern Monocoques
(Full Carbon Fiber Chassis ) ASTON MARTIN –One 77
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Part/Panel Nomenclature
Automobile
Stationary parts
Fastened parts
Welded parts
Press-fit
Adhesive-bonded parts
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• A part, also called a component, generally refers to an
individual unit used to build a vehicle.
• Several parts fastened together form an assembly.
• For example, a steering column assembly is made up of

the steering wheel, trim cover, air bag, turn signal
mechanism, and other parts.
• Stationary parts, such as the floor, roof, and quarter
panels, are permanently welded or adhesive bonded into
place. Hinged parts (the hood or trunk lid) and hinged
assemblies (doors) can open and close.
• Fastened parts are held together with various fasteners

(bolts, nuts, clips, adhesive, and so forth). Many parts, such
as the fenders, hood, and grille, are fastened or bolted into
place.
• Welded parts are permanently joined by heat fusing the

material so that it flows together and bonds when cooled.
Both metal and plastic parts can be welded.
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• Press-fit, or snap-fit, parts use clips or an interference
(friction) fit to hold parts together. This assembly method is
becoming more common to reduce manufacturing costs.
• Adhesive-bonded parts use a high-strength epoxy or

special glue to hold the parts together. Both metal and
plastic parts can be joined with adhesive. Structural
adhesive can also be used to bond parts together.
Unibody Design Factors

• Stressed hull structure:
• The unibody was a design concept used for the bodies of
aircraft. This type of structure is often compared to an
eggshell.
• Even when pressing hard on an eggshell lengthwise, it is

difficult to crush.
• This is because the full force is not concentrated in one

place but is dispersed effectively through the entire shell.
• In mechanics, this action creates a “stressed hull

structure.”
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• Crush zones / Crumple Zones are areas in the unibody
that are intentionally made weaker in order to collapse
during a collision.
• Crush zones provide some control of secondary damage

and a safer passenger compartment, because they are
engineered to collapse in a predetermined fashion.
• In a unibody structure the front and rear areas will crush,

whereas the passenger compartment area tends to stay
intact.

Impact energy flow in designed direction
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44

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8/20/19

Dr. Devender Kumar, AP, MED, TIET, Patiala

Vehicle Body Design

• The passenger compartment features two rows of seats

• The cargo compartment is typically in the rear.

• It is one of the most common car body styles.

Dr. Devender Kumar, AP, MED, TIET, Patiala

• 2 front, 2 back and one for the boot.

• This design is commonly found on small compact

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

• A pickup truck normally has a separate cab and

• Most pickup trucks use a front-engine, rear-

• Some are four-wheel drive.

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

• An SUV, or sport utility vehicle, has two wheel drive or

• This all-weather vehicle generally sits higher than

• Often classified as an off-road vehicle, the SUV is

Dr. Devender Kumar, AP, MED, TIET, Patiala

Station Wagon/ Estate

Dr. Devender Kumar, AP, MED, TIET, Patiala

Station Wagon/ Estate

• Also known as a estate , shooting-brake, or sports wagon,

• This is a 2-box style car with 4 pillars.

• You can imagine it to be a sedan with the roof extended

• A tailgate (door at the rear) enables bulky or long objects

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

• The van body design has a tall roof and a totally

• Vans can seat from two to twelve passengers,

• Basically, there are two sizes of vans: mini- and full-

• The most common are mini-vans

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

• The top folds down into an

people carrier hatchback

icles are used for the

Figure 1.31 Single-decker bus with front entrance

Figure 1.32 Single-decker bus chassis with engine laid on

Buses (omnibuses) A double-decker bus ca

Automobile Body Parts

Dr. Devender Kumar, AP, MED, TIET, Patiala

Automobile Body Parts

Dr. Devender Kumar, AP, MED, TIET, Patiala

Automobile Body Parts

Automobile Body Parts

Dr. Devender Kumar, AP, MED, TIET, Patiala

Automobile Body Parts

Dr. Devender Kumar, AP, MED, TIET, Patiala

Automobile Body Parts

Dr. Devender Kumar, AP, MED, TIET, Patiala

Automobile Body Parts

Dr. Devender Kumar, AP, MED, TIET, Patiala

Major Body Sections

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

• The center section is nicknamed the “greenhouse”

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

Dr. Devender Kumar, AP, MED, TIET, Patiala

• Without the skeleton, a human body would not be able to