L. D.

College of Engineering, Ahmedabad

Mr. P. B. Gujarati
M. Tech ( Industrial Process Equipment Design)

Course Content ( Design of Vehicle Bodies)

Vehicle Body Materials

Layout of the Design

Preliminary Design
Safety

Idealized structure and structural surface

Shear Panel Method
Symmetric and asymmetrical vertical loads in car

Longitudinal loads
Different loading situations
Load distribution on vehicle structure

Course Content ( Design of Vehicle Bodies)

Calculation of loading cases
Stress analysis of bus body structure under bending

and torsion
Stress analysis in integral bus body
Design of chassis frame
Rules and regulations for body
Recent safety measures
Testing of body

Design of Vehicle Bodies

Vehicle Design is broadly divided into Three Sections:
Engine & Transmission
Suspension
Body
Body Section has following sub-sections:
Body shell structure
Finish
Equipment

Design of Vehicle Bodies

Design of body shell involves
Problems of structural analysis (FEA)
Sheet metal forming and Welding
Finish sub-group involves
Paint and corrosion protection
Trim for internal finish,
Sound insulations
Equipment sub-group involves
Details such as door locks, windows, seats
Heating & ventilations
Instruments

Body Design
Body design involves
Materials
Types of loads and Loading conditions
Stress Analysis
Body design must always be guided by
Aesthetic considerations ( Styling)
Competition from other manufacturer
Aerodynamics
Cost optimizatoin

Vehicle Body Materials

Sheet Steel
Light Alloys
Plastics
Textiles
Glass
Rubber
Wood
Insulation Materials

Vehicle Body Materials

Sheet Steel:
Thickness range: 0.8 mm to 1.5 mm ( Most frequently

used material)
Steel type: Low Carbon Steel with 0.8 % C ( Good
weldability)
Cu & Ni added to increase anti-corrosive properties of
chrome
Sheet is obtained by deep pressing operations.

Vehicle Body Materials

Light Alloys:
Aluminium Alloys

Used for both as casting and sheet metal

Other Light alloys
Copper
Magnesium
Nickel

Vehicle Body Materials

Plastics
Can be divided into those obtained from

Large molecules and

Polymerization

Large Molecules

e.g. Celluloid ( Cellulose nitrate )

Applications: Decorative linings, anti glare glazing
and steering wheel

Vehicle Body Materials

Only Disadvantage : Highly inflammable
Alternate to celluloid are

Cellulose acetate
Cellulose butyrate

These are costlier than celluloid but they are

non-inflammable.

Vehicle Body Materials

Polymerization:
Bakelite ( which is Pheno - plast)
Suitable for casting and moulding
Insensitive to temp. and humidity changes
PVC: Used in Door Handles
Widely used plastics: Polymer resins
Good mech. Properties obtained when reinforced by

glass fibres.

Vehicle Body Materials

Textiles:
Cotton based fabrics traditional material for

internal trim of a vehicle

Shorter life but absorbs dust & other
impurities
Nowadays it is wholly replaced by plastic
called Imitation Leather

Vehicle Body Materials

Glass
Used in windows and doors
Safety glass

Laminated
which disintegrates into small pieces with blunt
edges during breakage.

Transparent plastics

Vehicle Body Materials

Rubbers:
Synthetic rubber
Resistant to fuel oil
Used in engine compartment near fuel

tank.
Seat cushions
Hardness of rubber is measured in IRHD (
International Rubber Hardness Degree)
E.g. 30 degree IHRD very soft rubber
100 degree IHRD hardest rubber

Vehicle Body Materials

Wood
Used before the introduction of plastics

Vehicle Body Materials

Insulating Materials:
Pre-requisites:
Low coefficient of thermal conductivity
High coefficient of vibration damping
But these are difficult to obtain simultaneously

in one material
If Material with included air bubbles, it
decreases elasticity i.e. low coefficient of vib.
Damping
Recent materials:
Polystyrene, felt, Urea Formaldehyde,
polyurethane