Automobile Module-1

Module 1- Introduction to Automobile Engineering
• The word ‘Automobile’ comes, via the French automobile from the ancient Greek
word (auto’s, “self”) and the Latin ‘mobiles’ (“Movable”), means a vehicle that
moves itself, rather than being pulled or pushed by a separate animal or another
vehicle.
• An automobile is a wheeled automobile vehicle carrying its own power unit
Prof. Shashidhara L C,
Dept. of ME, DSU
DEFINITION
• Automobile engineering is a branch of engineering which deals with everything
about automobiles and practices to propel them
• Automobile is a vehicle driven by an internal combustion engine and it is used for
transportation of passengers and goods on the ground. Automobile can also be
defined as a vehicle which can move by itself.
Examples: Car, jeep, bus, truck, scooter, etc.
1
History and development of Automobile
• Germany is the birth place of automobile.
• In 1872, American George Brayton invented the first
commercial liquid-fueled internal combustion engine. In
1876, Nicolaus Otto, working with Gottlieb Daimler and
Wilhelm Maybach, patented the compressed charge,
four-stroke cycle engine. In 1879, Karl Benz patented a
reliable two-stroke gas engine.
• The first automobile. On January 29, 1886, Carl Benz
applied for a patent for his “vehicle powered by a gas
Dept. of ME, DSU
engine.” The patent – number 37435 – may be regarded
as the birth certificate of the automobile.
• German inventor ‘Karl Benz’ is one of the many
individuals given credit for the creation of first
automobile. (1886)
• Nicolas Otto of Germany created the four stroke petrol
internal combustion engine.
• Rudolf Diesel Germany also invented the same four
stroke diesel engine. 2
127 Years of modern automobile evolution
• The electric car invented by inventor of electric motor
Hungarian and Gaston Plante who invented the lead acid
battery in 1859
• Benz also invented accelerator for speed
regulation, battery ignition system, spark
plug, clutch, gear shift and radiator for
cooling the engine.
• With these improvements, he started with
production of automobile, the first in the
world, in the year 1888.
• In 1893 the first four-wheeled automobile
Dept. of ME, DSU
was introduced by Benz. This was fitted with
four-stroke engine of his own design.
• Daimler and Mayback also produced about
thirty vehicles during 1890-1895
• The company of Daimler and Benz united
under the name of Daimler-Benz with a
commitment to keep that name till the year
2000 3
Mass Production
• Development of automotive technology was rapid.
• Large scale production of automobile was started by Ransom Eli Olds in 1902 and the
concept was vastly expanded by Henry Ford
• Engine 2898 cc was built by ford.
• Since 1920s, almost all automobiles have been mass produced resulting lower costs.
• In 1970s Volkswagen ‘’Beetle’’ was sold in large number of non-rusting cars.
Dept. of ME, DSU
4
Ransom E. Olds: Drawing the line
Oldsmobile Assembly Line Production | Courtesy of British V8
Vintage era vehicles include
Dept. of ME, DSU
Austin 7 (1922-1939), 5
Bugatti Type 35 (1924-1929),
Dept. of ME, DSU
6
Lancia Lambda (1922-1931), Hanomag (1925-1928)
Dept. of ME, DSU
7
Ford model A (1927-1931) Cadillac V-16 (1930)24.
Pre-World War II Era
8
Dept. of ME, DSU

Alvis Speed 20 Ford V-8 (Model B) Tatra
77
Dept. of ME, DSU
9
Bugatti Type 57 Rolls-Royce Phantom Volkswagen Beetle
III — V12 engine
Post War Era
• In this era an increasing focus on safety in the design of automobiles.
• The biggest developments of this era were the widespread use of
independent suspensions, fuel injection, more stream lined.
• Some cars are Ford Mustang (1964), Camaro (1967). In this era
Dept. of ME, DSU
Nissan, Toyota and BMW were also springing up.
10
modern era
• Through continuous improvement & the ingenious application of
new technology, the automobile reconfirmed and updated its
status as a triumph of engineering throughout the 20th century.
Dept. of ME, DSU
11
Current Scenario in Indian auto/ Ancillary
Industries
• As per India Brand Equity Foundation (IBEF), the auto-components industry
accounts for 2.3% of India's Gross Domestic Product (GDP). Auto Components
industry exports, which is currently valued at US$ 13.5 billion, is expected to grow at
an annual rate of 23.9% to reach US$ 80 billion by 2026.
• Auto ancillary industry means the industry closely link to the Automobile Sector.
Mostly, the Demand Swings in any of these segments (i.e. Cars, Two Wheelers,
Commercial Vehicles) which will impact on Auto ancillary demand.
Dept. of ME, DSU
• Industry Scenario:
India is expected to emerge as the world's third-largest passenger vehicle market by
2021. In FY 2018-19, sale of passenger vehicles has increased by 2.70%,
two-wheeler by 4.86% and three-wheeler by 10.27% as compared to FY 2017-18. In
April-March 2019, overall automobile exports grew by 14.50%.
• India's automotive sector is facing a crisis, with a sharp decline in sales forcing
manufacturers to cut back on production. Industry insiders warn that hundreds of
thousands of jobs are at risk. ... It was the worst sales performance since a 35% 12
decline in December 2000.
Components of automobile
• The basic structure
• Frame, Suspension system, Axles, wheels
• The power plant
• The transmission system
• The auxiliaries
Dept. of ME, DSU
• Ignition system, Batteries and generator
• The controls
• Steering system
• Brakes
• The superstructure
13
Classification of Automobile
Automobile can be classified as general consideration as follows:
1. On the Basis of Load.
2. On the Basis of Wheels.
3. On the basis of Fuel used.
4. On the Basis of Body Style.
Dept. of ME, DSU
5. On the basis of Transmission.
6. On the basis of Drive.
7. On the basis of Driving Axle
8. Position of Engine
14
1. On the Basis of Load:
• Heavy transport vehicle (HTV) or heavy motor vehicle (HMV),
• Examples –
Dept. of ME, DSU
• Light transport vehicle (LTV), Light motor vehicle (LMV),
• Examples -
. 15
2. On the Basis of Wheels :
• Two wheeler vehicle, for example : Scooter, motorcycle, scooty etc.
• Three wheeler vehicle, for example : Autorickshaw
• Three wheeler scooter for handicaps and tempo, etc.
• Four wheeler vehicle, for example : Car, jeep, trucks, buses, etc.
• Six wheeler vehicle, for example : Big trucks with two gear axles.
Dept. of ME, DSU
3. On the basis of Fuel Used:
• Petrol vehicle, e.g. motorcycle, scooter, cars, etc.
• Diesel vehicle, e.g. trucks, buses, etc.
• Electric vehicle which use battery to drive.
• Steam vehicle, e.g. an engine which uses steam engine. 16
• Gas vehicle, e.g. LPG and CNG vehicles, where LPG is liquefied
4. On the basis of body style:
• Closed cars such as salon, coupe
• Open cars like sports car, convertible car etc.
Dept. of ME, DSU
• Special styles such as estate car, station wagon Etc.
17
5. On the basis of Transmission:
• Conventional vehicles with manual transmission, e.g. car with 5
gears.
• Semi-automatic : having two pedal transmission using manual
operation of standard gear box, with automatic clutch control.
These are absolute now.
Dept. of ME, DSU
• Automatic : In automatic transmission, gears are not required
to be changed manually.
6. On the basis of Drive:

• Left hand drive 18
• Right hand drive
7. On the basis of Driving Axle
• Front wheel drive
• Rear wheel drive
• All wheel drive
8. Position of Engine:
Dept. of ME, DSU
• Engine in Front - Most of the vehicles have engine in
the front. Example :most of the cars,
• Engine in the Rear Side - Very few vehicles have
engine located in the rear. Example : Nano car,. 19
20
Dept. of ME, DSU

Types of chassis layout
• A chassis is the basic framework of your vehicle. Sometimes the chassis is
only the frame, while other times it includes the wheels, transmission,
and sometimes even the front seats. A chassis is one of the most
important components of a vehicle, without which the car would have no
structure.
• Chassis are classified as

1. On the basis of control chassis
• Conventional control chassis.
• Semi-forward control chassis.
Dept. of ME, DSU
• Fully forward control chassis.
2. On the basis of engine (power plant) location
• Engine fitted at front
• Engine fitted at back
• Engine fitted at center
• Engine fitted at front but crosswise
3. Number of wheels fitted in the vehicles and number of driving
wheels
• 4x2 drive chassis vehicle
• 6x2 drive chassis vehicle 21
Conventional control chassis, in which engine is
mounted in front of the driver’s cabins. This type of
arrangements avoids full utilization of space
Dept. of ME, DSU
22
Semi-forward control chassis, in which engine is so mounted
that half of it is in the drivers cabin whereas the other half is
in front, outside the drivers cabin.
Dept. of ME, DSU
23
Fully forward control chassis, in which engine is mounted
completely inside the driver’s cabin obviously maximum
utilization of space is achieved in this type arrangements.
Example Tata E series.
Dept. of ME, DSU
24
Engine at front & drive is given to the wheels from the
REAR
• Enough space is available for luggage
behind the rear seat.
• The weight of vehicle is well balance.
• Increased efficiency of cooling system.
Engine is fitted at front & drive is given to front wheels
Dept. of ME, DSU
crosswise
• Low floor is available
• Vehicle has more road holding
capacity
• Clutch, gear box & differential
are usually made as one unit 25
thereby cost is reduced
Engine fitted at the center of the
•chassis
Drive is given to the rear
• The layout has a tendency toward being heavier in the rear than the
front, which allows for best balance to be achieved under braking.
• This arrangement provide full space of floor for use
• this layout is heavily employed in open-wheel Formula racing as well
as purpose-built sports racing cars.
Dept. of ME, DSU
26
Engine fitted at back
• Flat floor is available since long propeller shafts are eliminated
• With elimination of propeller shaft the center of gravity
lowered giving stable driving
• Better adhesion on road specially when climbing hill
• As the result of grouping of the engine with clutch, gear box,
Dept. of ME, DSU
differential the repair and adjustment become difficult due to
congestion at the rear
27
FRAME :
• A frame is the main structure of the chassis of a motor vehicle. All
other components fasten to it; a term for this is design is
body-on-frame construction.
• In 1920, every motor vehicle other than a few cars based on
motorcycles had a frame. Since then, nearly all cars have shifted to
unit-body construction, while nearly all trucks and buses still use
frames.
CHASSIS :
Dept. of ME, DSU
• chassis is a skeletal frame on which various mechanical parts like
engine, tires, axle assemblies, brakes, steering etc. are bolted. The
chassis is considered to be the most significant component of an
automobile.
• It is the most crucial element that gives strength and stability to the
vehicle under different conditions. Automobile frames provide
strength and flexibility to the automobile.
• The backbone of any automobile, it is the supporting frame to which
the body of an engine, axle assemblies are affixed. Tie bars, that are
essential parts of automotive frames, are fasteners that bind
different auto parts together 28
Vehicle Frame
A frame is a main Structure of the chassis of a motor
vehicle. All other components fasten to it
Function of Frame
Dept. of ME, DSU
• To support chassis components and the body
• To withstand the static and dynamic load of different components of
chassis.
• To withstand load of the body and passengers/goods carried in body
• To withstand stress caused due to uneven road conditions
• To withstand force caused due to turning of vehicle and sudden 29
braking or acceleration.
Classification of Frames
• Conventional frame
• Integral or unitized frame
• Half integral or semi-integral frame
Dept. of ME, DSU
30
Conventional frame
• It has two long side member and 5 to 6 cross members joined together with
the help of rivets and bolts. Used in trucks, bus and SUV cars and Bigger
vehicles
• The frame sections are generally
1. Channel section – good resistant to bending.
2. Tabular section – good resistant to torsion.
Dept. of ME, DSU
3. Box section – good resistance to both bending to torsion
4. I- section- for heavy duty applications
5. Hat section – for cross members
31
Integral Frame
• This frame is used nowadays in most of the cars called frameless or chassis
less or unitized construction. Floor assembly and frame form one integral
part.
• Need of the heavy side members are eliminated ,which is used in
conventional frame & the floor is strengthened by cross members & body ,
all welded together.
Dept. of ME, DSU
• In some cases sub-frames are also used on which various chassis
components are mounted. This sub-frames are supported by main frame.
• The main purpose of sub-frame are to provide isolation , flexibility &
simplified production.
• So, in this type of construction all components like cross member , floor ,
body are welder or bolted together as one assembly.
• This type of construction gives more strength & rigidity. 32
• Only disadvantage is difficulty in repairing.
Integral Frame
33
Dept. of ME, DSU

Semi-Integral Frame
• In some vehicle half frame is fixed in the front end on which
engine gear box and front suspension is mounted
• It has the advantage when the vehicle is met with accident the
front frame can be taken easily and replace the damaged
chassis frame
Dept. of ME, DSU
• This type of frame used in European and American cars
34
Constructional details
• Frame is made up of long two members called side members riveted
together with the help of number of cross members.
• In simplified figure the longitudinal (long)
member A and cross member B.
• The frame is upswept at the rear and front to
accommodate the movement of axles due to
Dept. of ME, DSU
springing. It also keep chassis height low
• The frame is narrowed down at front to have a
better steering , which gives a smaller turning
circle
• The extension of the chassis frame ahead of the
front axle is called front overhang. Whereas
extension beyond the rear axle is called rear 35
overhang
• C are brackets supporting the body
• E1 acts as bearing for spring shackles,
they also take bumper brackets.
• Brackets E are meant for mounting
the spring.
• The engine clutch and transmission
are all bolted together to form one
Dept. of ME, DSU
rigid assembly which is mounted
usually on the frond end of frame
• Engine is supported on frame by
means of rubber blocks, this helps
isolates the engine from road shocks.
And body from engine vibrations 36
Types of frames
• 1. Ladder Frame
• 2. Backbone Frame
• 3. X-frame
Dept. of ME, DSU
• 4. Perimeter Frame
• 5. Platform Frame
• 6. Unibody (or) Unit body
• 7. Sub Frame
37
1.Ladder Frame
• The ladder frame is the simplest and oldest of all designs.
• It consists of two symmetrical rails, or beams, and cross member connecting
them.
• Originally seen on almost all vehicles, the ladder frame was gradually
phased out on cars around the 1940s and is now seen mainly on trucks.
• This design offers good beam resistance because of its continuous rails from
front to rear, but poor resistance to torsion.
Dept. of ME, DSU
• Also, the vehicle's overall height will be higher due to the floor pan sitting
above the frame instead of inside it
38
39
Dept. of ME, DSU

2.Backbone frame
• Backbone frame is a type of an automobile construction frame
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.
Dept. of ME, DSU
• A body is then placed on this structure.
40
3.X-frame
• This is the design used for the full-size American models of General Motors.
• In which the rails from alongside the engine seemed to cross in the passenger
compartment, each continuing to the opposite end of the cross member at the
extreme rear of the vehicle.
• It was specifically chosen to decrease the overall height of the vehicles, and to
increase in the space for transmission.
• The X-frame was claimed to improve on previous designs, but it lacked side rails
Dept. of ME, DSU
and thus did not provide adequate side impact and collision protection.
• So This design was replaced by perimeter frames.
41
4.Perimeter frame
• Similar to a ladder frame, but the middle sections of the frame
rails sit outboard of the front and rear rails.
• This was done to allow for a lower floor pan, and therefore
lower overall vehicle in passenger cars.
• In addition to the perimeter frame allows lower seating
positions when that is desirable, and offers better safety in the
event of a side impact.
Dept. of ME, DSU
• However, the design lacks stiffness, because the transition areas
from front to center and center to rear reduce beam and
torsional resistance.
42
5.Platform Frame
• This is a modification of the perimeter frame in which the passenger
compartment floor and often the luggage compartment floor were
permanently attached to the frame, for extra strength.
• Neither floor pieces were sheet metal straight off the roll, but had
been stamped with ridges and hollows for extra strength.
• This was used by the Germans on the Volkswagen Beetle and the
Dept. of ME, DSU
Mercedes-Benz "Ponton" cars of the 1950s and 1960s, where it was
called in English-language advertisements as the "frame floor".
43
6.Unitized frame body
construction
• Integral frame is also called unitized frame
• With unitized body construction, the front, rear and side rails are welded
together with the floor pan, cross members and torque boxes to form a
single “unit,” whereas body-on-frame construction has two pieces, the body
and the frame
Dept. of ME, DSU
• This become the preferred construction for mass production especially in the
wake of energy crises of the 1970s and mid 2000s oil price increases
• Commonly used for car and mini van construction in which a solid robust
frame is not required
• Provides an advantage of less vehicle weight that helps contribute to
44
performance and fuel economy.
45
Dept. of ME, DSU

unitized body
Integral Frame or
46
Dept. of ME, DSU

7.Sub frame
• A sub frame is a structural component of a vehicle.
• Such as an automobile or an aircraft, that uses a separate
structure within a larger body-on-frame or unit body to carry
certain components, such as the engine, drivetrain, or
Dept. of ME, DSU
suspension.
• The sub frame is bolted and/or welded to the vehicle.
• When bolted, it is sometimes equipped with rubber
• bushings or springs to dampen vibration.
47
• The principal purposes of using a subframe are, to spread high chassis loads
over a wide area of relatively thin sheet metal of a monocoque body shell,
and to isolate vibration and harshness from the rest of the body.
• For example, in an automobile with its power train contained in a subframe,
forces generated by the engine and transmission can be damped enough that
they will not disturb passengers.
• As a natural development from a car with a full chassis, separate front and
rear subframes are used in modern vehicles to reduce the overall weight and
cost.
Dept. of ME, DSU
48
Loads acting on vehicle frame
1. Short duration Load – While crossing a broken patch.
2. Momentary duration Load – While taking a curve.
3. Impact Loads – Due to the collision of the vehicle.
Dept. of ME, DSU
4. Inertia Load – While applying brakes.
5. Static Loads – Loads due to chassis parts.
6. Over Loads – Beyond Design capacity.
49
Loads acting on vehicle frame
• Weight of the vehicle and passengers, which causes vertical bending of the
side members
• Vertical loads when the vehicle comes across a bumps or hollow, which
results in longitudinal torsion due to one wheel lifted (or lowered) with
other wheels at usual road level.
• Loads due to road camber, side wind, cornering force, while taking turn,
Dept. of ME, DSU
which results in lateral bending of side members.
• Load due to wheel impact with road obstacles may cause that particular
wheel to remain obstructed while the other wheel tends to move forward,
distorting the frame to parallelogram shape
• Engine torque and braking torque tending to bend the side members in the
vertical plane
• Sudden impacts loads during a collision, which may result in general 50
collapse
Details of chassis materials
• Materials selection of Chassis frame depends on:
• Type of Vehicle (Heavy, Light)
• Chassis Design (Engine components location)
• Manufacturing company
Dept. of ME, DSU
• Why materials are important
• Fuel economy
• Recommended materials
• Cast iron (for Heavy vehicles)
• HSS, Steel (Medium vehicles)
• Aluminum alloys (Light Vehicles) 51
Materials for chassis frame
52
Dept. of ME, DSU

53
Dept. of ME, DSU

What material properties are important in choosing
frame material?
• First, there are three types of material properties:
Physical - Density, color, electrical conductivity, magnetic
permeability, and thermal expansion.
Mechanical - Elongation, fatigue limit, hardness, stiffness,
Dept. of ME, DSU
shear strength, tensile strength, and toughness.
Chemical - Reactivity, corrosion resistance, electrochemical
potential, irradiation resistance, resistance to acids,
resistance to alkalis, and solubility.
54
Question bank
1. How is a frame different from a chassis? Discuss the design aspects and salient features of
frame?
2. What are the loads coming on frame? With the help of line diagram, explain the construction,
briefly.
3. Enumerate the different types of chassis and frame?
4. Define automobile and explain its classification
5. What material properties are important in choosing frame material? why material selection is important
?
Dept. of ME, DSU
6. Describe components of automobile in detail?
7. Explain detail classification of automobile on the basis of transmission system?
8. Explain detail classification of Classify automobile on the basis of engine position?
9. What is vehicle frame and its function?
10. Differentiate ladder frame and backbone frame with suitable diagram?
11. Differentiate ladder frame and perimeter frame with suitable diagram?
12. Explain sub frame and uni body fame in detail?
13. Briefly explain types of chassis layout with reference to power plant location?
14. Explain conventional frame and importance of different frame sections?
15. What is the benefits of front engine than back engine? 55
16. What is the benefits of back engine than front engine?
Assignment 1 – Last day of submission
(16/8/18)
1. current scenario in Indian auto/ ancillary industries?
2. Role of the automobile industry in national growth?
Dept. of ME, DSU
56

Automobile Module-1

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Automobile Module-1

Uploaded by

Copyright:

Available Formats

Module 1- Introduction to Automobile Engineering

Dept. of ME, DSU

• Open cars like sports car, convertible car etc.

6. On the basis of Drive:

Dept. of ME, DSU

• Chassis are classified as

Engine is fitted at front & drive is given to front wheels

Dept. of ME, DSU

Dept. of ME, DSU

Dept. of ME, DSU

Dept. of ME, DSU

Dept. of ME, DSU

Dept. of ME, DSU

You might also like