MANUFACTURING OF

A CAR BODY
A PROJECT REPORT
SUBMITTED IN COMPLETE FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF THE DEGREE
OF
BACHELOR OF TECHNOLOGY
IN
WORKSHOP PRACTICES
SUBMITTED BY:
SHIVAM AGRAWAL
2K20/A15/10
VANSH AGGARWAL
2K20/A15/48
UNDER THE SUPERVISION OF
PROF. PRAVIN KUMAR
WORKSHOP PRACTICES

DELHI TECHNOLOGICAL UNIVERSITY

(FORMERLY DELHI COLLEGE OF ENGINEERING)
BAWANA ROAD, DELHI-110042
 CANDIDATE’S DECLERATION

We, (Shivam Agrawal,2k20/A15/10, Vansh Aggarwal,

2K20/A15/48) students of B. Tech. hereby declare that the
project Dissertation titled ”Manufacturing of a Car body” which
is submitted by us to the Department of Workshop practices,
Delhi Technological University,
Delhi in partial fulfilment of the requirement for the award of
the degree of Bachelor of Technology, is original and not copied
from any source without proper citation. This work
has not previously formed the basis for the award of any Degree,
Diploma Associateship, Fellowship or other similar title or
recognition.

Place: Delhi
Shivam Agrawal(2k20/A15/10)

Date: Vansh Aggarwal(2k20/A15/48)

WORKSHOP PRACTICES
DELHI TECHNOLOGICAL UNIVERSITY
(FORMERLY DELHI COLLEGE OF ENGINEERING)
BAWANA ROAD, DELHI-110042
 CERTIFICATE

I hereby certify that the project Dissertation titled

”Manufacturing of a Car body“ which is
submitted by Shivam Agrawal, Vansh Aggarwal
(2K20/A15/10, 2K20/A15/48) [Worshop Practices], Delhi
Technological University, Delhi in complete fulfilment of the
requirement for the award of the degree of the Bachelor of
Technology, is a record of the project work carried out by the
students under my supervision. To the best of my knowledge
this work has not been submitted in part or full for any Degree
or Diploma to this University or elsewhere.

Place: Delhi
Prof. Pravin Kumar
Date:

WORKSHOP PRACTICES
DELHI TECHNOLOGICAL UNIVERSITY
(FORMERLY Delhi College of Engineering)
Bawana Road, Delhi-110042
 ABSTRACT

In our project work we will discuss about various aspects of

car body making like the material used for making cars and
processes involved. We will discuss about the properties of
materials used in the structure making.
The processes involved in making car body involves:
1. Bending
2. Drawing
3. Stamping
4. Extrusion
5. Forging
6. Welding
7. Finishing
We will also discuss about the structure and shape of car body
which gives several advantages.

Through this project we will learn about various

Manufacturing process in detail.
 INTRODUCTION

In our project work we have discussed about various aspects of automobile

manufacturing especially car body making like the material used for making
cars like carbon steel and the processes involved. We have discussed about
the properties of materials used in the structure making. We have also looked
into the design making of a car.
Our prime focus has been to deal with the manufacturing processes
involved in making it.
We have also discussed about various tools which come into play while
all the processes are carried on.
 Material Used In Car Making:

The main materials used for making car parts are steel, aluminum,
magnesium, copper, plastic and carbon fiber and composites. ( A composite
is composed of high–performance fibre (such as carbon or glass) in a matrix
material (epoxy polymer) that, when combined, provides enhanced properties
compared with individual)
The main factors for selecting these different materials are Durability,
Mechanical resistance, easy manufacturing, affordability, Chemical and
thermal resistance etc.
Majorly steel is used because it has capability to absorb impact energy and
also steel allows better stamping and various welding techniques. Aluminum
is used because of its low density and high specific energy performance and
good specific strength. Carbon fiber are widely used in making chassis of
sports car because of its high tensile strength, lightweight, toughness.
Manufacturing processes used in
making metal chassis :
Here, we explain the basic processes involved in car making.
The processes
involved are :
➢ Sheet
metal working

➢ Forging
➢ Welding

➢ Finishing etc.
 Sheet metal working:

Sheet metal is one of the basic forms used in metal working. It can
be cut, bent into number of shapes.
This is one of the fundamental requirements for a car. There are
various processes involved in sheet metal working.

Some major processes are explained below:

1. Bending: Bending is a metal forming process in which a
force is applied to a piece of sheet metal, causing it to bend at
angle and form the desired shape. There are two types of
bending V-Bending and Edge bending.
 In Fig.:
V- bending
Edge bending

2. Shearing : It is a process in which unwanted material is

trimmed and removed from the sheet metal. The process
makes use of equipment such as Bench shear for extreme
precision in the shearing process.

In fig.: Shearing
3. Blanking : It is a process in which a flat geometric shape(also
called blank) is carved out by feeding a metal sheet into a press
and die. A blank is punched out of the metal sheet.
 In fig.: Blanking

• Punching
operations are
similar to
blanking except
that the shape cut out is cylindrical.
4. Slitting : It is a shearing processes in which sheet metal is cut
out by two opposing circular blades. Slits are produced in
straight or curved path. No scrap material is produced.

In fig.: Slitting
5. Perforating : Punching a close arrangement of large number
of holes in a single operation.

In fig.: Perforating

6. Embossing : Sheet metal embossing is a stamping process in

which sunken or raised design is produced in metal sheet.

In fig.: Embossing

7. Cutting off: It is a shearing operation in which blanks are

separated from a part from the remaining sheet, without
producing any scrap.
 In fig.: Cut off

8. Deep drawing : Deep drawing is a metal forming process in

which sheet metal is stretched into the desired shape. A tool
pushes downward on the sheet metal, forcing it into a die
cavity in the shape of the desired part .

In fig.: Deep Drawing

9. Roll forming: Roll forming is a continuous bending operation

in which a long strip of sheet metal is passed through sets of
rolls mounted on consecutive stands, each set performing only
an incremental part of the bend, until the desired cross-
 section profile is obtained. Roll forming is ideal for producing
constant-profile parts with long lengths and in large quantities.

In fig.: Rolling process

10.Stretching process: Stretch forming is a metal forming

process in which a piece of sheet metal is stretched and bent
simultaneously over a die in order to form large bent parts.

In Fig.: Stretching process

These are some important sheet metal working processes.

 Forging
Forging is a metalworking process in which deformation of the work
piece is carried out by compressive forces applied through various
equipment. This process is capable of producing a number of shapes
and structures required for making a car body.
The forging processes can be done at room, warm or high
temperatures.
Different Types of forging are discussed below:
There are two main types of forging:
➢ Hot Forging:
It requires the metal to be heated above its recrystallisation
temperature. Temperature can go as high as 2300° F.
Excessive heat decreases yield strength and improves ductility.
➢ Cold forging:
Metral is forged at room temperature i.e. below its
recrystallisation temperature. Cold forging is better in
dimensional control, product uniformity and surface finish.

Apart from this there are various forging processes

described below:
• Open die Forging process
Open die forging is the process of deforming a piece of metal between
multiple dies that do not completely enclose the material. The metal is
altered as the dies “hammer” or “stamp” the material through a series of
movements until the desired shape is achieved.
• Closed die forging process
Closed die forging ( impression die forging), employs the use of moulds.
These moulds are attached to an anvil while a hammer forces molten
metal to flow into the cavities of the die. Multiple strikes and/or die
cavities are often used when forging complex geometries. Closed die
forging also provides exceptional strength over alternative methods.
Common applications of closed die forging include the production of
automobile components and hardware tools.

• Press forging
The metal sits on a stationary die while a compression die applies
continuous pressure, achieving the desired shape

• Rolling forging
Roll forging is the process of increasing rods or wires in length
 WELDING
Welding is a process in which two or more parts are fused together
to form a permanent joint. It is used in automobile manufacturing,
aircraft materials etc.
TYPES:
1.PLASTIC WELDING:
By use of pressure the joints are created.
2.FUSION WELDING :
Metal at joint is heated with another metal and then is allowed to cool down.

Various welding processes are :

The main types of automotive welding are MIG, TIG, and Arc welding.
Understanding the differences between these welding methods is crucial and
will help you determine which type of welding is necessary to complete your
repair.

MIG Welding
MIG (Metal Inert Gas) welding is the most common welding method out
there today. This welding method requires a gas shield and filler
material, the latter of which is fed through a wire that runs through the
welder. This makes it easy to weld, since the tool can be held with one
hand.
MIG Welding, which is also known as “Gas Metal Arc Welding,” is a
form of arc welding. This welding technique relies on electricity to fuse
materials together to create a weld. In more technical terms, arc
welding uses a power supply to create an electric arc between the base
metal and an electrode. The higher the electric voltage, the more
powerful the weld.
MIG welders are faster than other types of welders, which makes them
a great choice for quick repairs and increased productivity.
Additionally, the MIG welding technique is applicable for a wide range
of metals, making this type of welding a popular choice among body
shops everywhere.
 Stick Welding
Stick welding, also called Shielded Metal Arc Welding, is an older type
of welding that is not as common today as MIG welding. Like MIG
welding, stick welding is a form of arc welding; however, this welding
method is more suitable for heavier metals such as iron and steel. It is
not suitable for lighter metals such as aluminum.

Although stick welding is one of the earliest forms of welding, many

repairers opt for other welding methods due to poor weld quality. Stick
welding is more likely to result in errors such as weld spatter, cracking,
and low-quality fusion. However, practicing this welding technique will
help you improve your stick welding skills.

TIG Welding
TIG welding, or “Tungsten Inert Gas” welding, is ideal for more refined
and advanced welding projects. This type of welding has been around
since World War II and uses a tungsten electrode to create the weld.
Repairers must use two hands during this welding process, as one
operates the filler and the other operates the welding nozzle.

TIG welding works best for aluminum and thin sheets of

stainless steel, which makes this skill a valuable one to have
as cars are becoming lighter and lighter.
 DESIGN AND ANALYSIS OF CAR BODY USING CFD
SOFTWARE
Conference Paper · May 2015

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 DESIGN AND ANALYSIS OF CAR BODY USING CFD SOFTWARE
Stjepan Galamboš1, Jovan Dorić2

Summary: This paper presents the method of modeling and design of the car body using modern software tools, in
order to obtain as much as possible realistic models suitable for further analysis. The work is based on elements of
aerodynamics and vehicle dynamics and impact of external influences on it. Also, model verification with numerical
calculations was conducted in this research. After a detailed analysis of the obtained results with CFD, it was concluded
that the model of the car with the geometric simplifications meets the criteria of accuracy and this was completely
capable for the further course of the analysis. This paper presents the procedures for obtaining the results from a
combination of more modern tools (CCM+), which is certainly a trend in modern ways of designing and constructing.
Key words: Aerodynamics, Car's body, CatiaV5, CFD, analysis

1. INTRODUCTION
Aerodynamics represents a special scientific filed that has a huge impact on modern automotive engineering.
Aerodynamics deals with the influence of external factors on the observed object, as well as the shape of the object in
order to achieve the desired performance. The aerodynamics forces and coefficients heavily influence the behavior of
vehicles on the road. The main three aerodynamics forces are Drag Force, Lift Force and Lateral Force. Every one of
these forces has angular rotation around its axis, that are Roll, Pitch and Yaw. [1] [2]
Property testing of this work is the previously modeled BMW’s car body, type Z4. This vehicle model was
made on the actual model and its technical documentation. After modeling, testing facility was introduced in a simplified
version of the wind tunel, in which the means of simulations performed a detailed analysis of the impact of the external
factors on the subject. After that, the results are analyzed and comparisons and verification of numerical calculations
for that vehicle are performed.

693

Stjepan Galamboš, Jovan Dorić

2. MODELING OF CAR BODY

In order to carry out an analysis and subsequent corrections of the shape of the car body, it is necessary to
establish a model using CAD 3d modeling software first. The model must be made in accordance with the terms of the
CFD (Computer Fluid Dynamics) software which will be conducted postprocesing. Based on previous experience, as
well as CatiaV5 CAD software, the use of which is familiar with the top leaders of the automotive industry. [3]
First, it is necessary to introduce a set of image projections models in the correct position, based on the actual
dimensions, since the true model is in scale 1:1. Next, figure 1 ilustrated the image projections in the Catia software.
After that, the modeling process was included by basically making car’s body from one solid cuboid. Below that solid

1 MSc, Stjepan Galamboš, Novi Sad, University in Novi Sad, Faculty of Technical Sciences, (stjepan.galambos@gmail.com)

2 Dr, Jovan Dorić, Novi Sad, University in Novi Sad, Faculty of Technical Sciences, (jovan_d@uns.ac.rs)
cuboid parts were removed with Pocket Catia’s function on the real dimensions by image projections. That step is
illustrated on the Figure 2. After this step, car’s body model is ready for introduction into CFD software for further
analysis.

Fig. 1 Image projections Fig. 2 Final CAD model of car’s body

3. AERODYNAMICS ANALYSIS WITH CFD SOFTWARE

Star CCM+ is one of the leading softwares in the CFD family which, in addition to calculating the same
aerodynamics and the impact of air flow to the observed model, can perform detailed calculations and analysis in the
field of mechanics, thermodynamics, heat transfer process inside of the shock of large systems, etc. [4]
After the introduction of the CAD model, it is necessary to access its detailed settings in order to
achieve the desired goal. One of the main adjustment steps is making excellent model regions. Shere the
model regions or boundary of the model is performed using the Mesh function in CFD software. Adjustment
of Mesh was made based on the recommendations from the literature[4]. Figures 3 illustrated made Mash
for wind tunel in generally and only on the vehicle model.

Fig. 3 Ilustration of Mash function by CFD software

694
Design and Analysis of Car Body Using CFD Software

4. CFD POSTPROCESING AND RESULTS OF ANASYSIS

Display and processing of the obtained simulation results are divided into three categories,
according to the speed of air flow in the wind tunnel (80, 120 and 160 km/h), and the reciprocal of the
velocity of the vehicle on the other side. This is followed by another part reserved for results and
discussions.
Next, figure 4 illustrated the field of air flow velocity in wind tunnel, and field of pressure for air
speed of 80 km/h. That illustration was made cross section, in the central longitudinal axis of the wind
tunnel.

Fig. 4 Illustration of velocity and pressre fields in wind tunel

 Because of the great similarity between the illustranion images for flow velocity of 80, 120 and 160
km/h, the display of the obtained values is limited to the tabulation. All results concerning forces and
coefficients are illustrated in next table 1.

Table 1 Comparative results

Air Velocity in Wind Tunnel 80 km/h 120 km/h 160 km/h
Frontal area of car model (Const.) 1,774 m2 1,774 m2 1,774 m2
Air Drag Force Fd 200,08 445,89 N 791,73 N
Lift Force Fl 158,85 358,42 N 644,42 N
Drag Coefficient Cd 0,370 0,367 0,367
Lift Coefficient Cl 0,294 0,295 0,298
5. CONCLUSION
Based on the examined values of forces and coefficients obtained from analytical and CFD simulation, it
can be concluded that varying the geometry of the model contributes significantly on the change in the
values of forces and coefficients. It is shown that on the basis of a simplified model and a very accurate
and precise tuning characteristics, related to physics and network models, CFD software can achieve the
desired accuracy. At this level of testing aerodynamic model has shown its positive side simplifications,
but if it was entered into a detailed analysis of individual components or parts of the car body modeling
should be raised to a higher level of detail . Three specified speeds are major break-even rate at which
one can clearly see all of the above phenomena through force and the coefficient on the basis of which we
can make further analysis. Furthermore, software packages that are presented in this paper and their
complexity evidenced by the fact that everything is demanded of them in terms of work represent only a
small part of their real capabilities, which require a very long and arduous period of learning and training.
Also made a very good connection between the

695

Stjepan Galamboš, Jovan Dorić

software that has very differing Windows spectra areas of work and activities, which certainly is one of the modern
methods of design and construction.

REFERENCES
[1] Milovanović M. (2013) Projektovanje karoserije automobila – monografija. Kragujevac. Srbija
[2] Gillespie T. (1992) Fundamentals of Vehicle Dynamics. Society of Automotive Engineers. USA
[3] Tickoo S. (2005) CatiaV5R17 for Designers. Purdue University Calumet and CADSIM Technologies.
USA
[4] Anonim 1. (2013) User Guide Star-CCM+. CD-Adapco Coorporation. Melville. USA.
 [5] REFERENCES
[6] https://www.egr.msu.edu/~pkwon/me478/sheetforming.pdf

[7] https://www.thomasnet.com/articles/custom-manufacturing-

fabricating/what-is-forging/
[8] https://www.mech4study.com/2017/04/what-is-forging-process-

operation-types-application-advantages-and-disadvantages.html
[9] https://www.twi-global.com/technical-knowledge/faqs/what-is-

welding
[10] https://www.tws.edu/blog/welding/what-is-tig-welding/

[11] https://www.twi-global.com/technical-knowledge/job-

knowledge/mig-welding-004
[12] https://gowelding.org/welding/mig-gmaw/