Automotive design

Automotivedesign
Chassis*design
*pronounced:chase singular
chasez plural

Introduction
Loadsduetonormalrunningconditions:
Loads due to normal running conditions:
Vehicletransverseonunevenground.
Manoeuverperformedbydriver.
p
y

Fivebasicloadcases:
Bendingcase
Bending case
Torsioncase
Combinedbendingandtorsion
g
Lateralloading
Foreandaftloadingg

Bending

Payload
Occupants

Duetoloadingin
vertical(XZ)plane.
Duetoweightof
components along
componentsalong
thevehicleframe.
Staticconditionvehicle
structurecanbetreated
as2Dbeam.

Fueltank

Engine

Vehicleisapproximatelysymmetricinxyplane.
pp
y y
yp

Unsprung mass
Componentsliebelowchassis
Donotimposeloadsinstaticcondition.
Do not impose loads in static condition

Wheels/
b ki
braking

Suspension

Bendingmoment/Shearforcediagramofatypical
passengervehicle
hi l

Bending
Dynamicloading:

Inertiaofthestructurecontributesintotalloading
Alwayshigherthanstaticloading
Roadvehicles:2.5to3timesstaticloads
Offroadvehicles:4timesstaticloads

Example:
E
l

m
g

Staticloads

Vehicleatrest.
Moving at a constant velocity on a even road.
Movingataconstantvelocityonaevenroad.
Canbesolvedusingstaticequilibriumbalance.
Resultsinsetofalgebraicequations.

Dynamicloads
Vehiclemovingonabumpyroadevenatconstantvelocity.
V hi l
i
b
d
t
t t l it
Canbesolvedusingdynamicequilibriumbalance.
Generallyresultsindifferentialequations.

m
g

m
a

Torsion
Whenvehicletraverseonan
unevenroad.
d
Frontandrearaxles
experiencesamoment.
Pure
simple torsion:
Puresimpletorsion:
Torqueisappliedtooneaxle
andreactedbyotheraxle.
Frontaxle:anticlockwise
torque(frontview)
Rearaxle:balanceswith
clockwisetorque
Resultsinatorsionmoment
Results in a torsion moment
aboutx axis.

Inrealitytorsionisalways
accompaniedbybendingdue
t
togravity.
it

Rearaxle
l

Frontaxle

Torsion
Rearaxle
l

Frontaxle

Combined bending and torsion

Combinedbendingandtorsion

Bendingandtorsionalloadsaresuper
imposed.

Loadingsareassumedtobelinear

Onewheelofthelightlyloadedaxleisraised
onabumpresultintheotherwheelgooff
ground.
All loads of lighter axle is applied to one
Allloadsoflighteraxleisappliedtoone
wheel.
Duetonatureofresultingloads,loading
symmetrywrt xzplaneislost.
RR canbedeterminedfrommoment
balance
balance.
RRstabilizesthestructurebyincreasingthe
reactionforceonthesidewherethewheelis
offground.
Themarked

Bendingg

Torsion

Sideisoffground
Sidetakesallloadoffrontaxle
Sidesreactionforceincreases
Sidesreactionforcedecreases

tobalancethemoment.

Combinedbendingandtorsion

Lateral loading
Lateralloading

Lateral loading
Lateralloading

Foramoderncart=1.45mandh
=0.51m.
0 51 m
Criticallateralacceleration=1.42
g
y
Inrealitysideforceslimitlateral
accelerationislimitedwithin0.75
g.
Kerb bumpingcauseshighloads
and results in rollover
andresultsinrollover.
Widthofcarandreinforcements
providessufficientbending
stiffnesstowithstandlateral
forces.
forces
Lateralshockloadsassumedto
betwicethestaticverticalloads
onwheels.

Longitudinal loading
Longitudinalloading
Whenvehicleacceleratesand
d l t i ti f
deceleratesinertiaforceswere
generated.
Acceleration Weight
transferred from front to back
transferredfromfronttoback.
Reactionforceonfrontwheelis
givenby(takingmomentabt RR)

Deceleration Weight
transferredfrombacktofront.
Reaction
Reactionforceonfrontwheelis
force on front wheel is
givenby

Longitudinal loading
Longitudinalloading
Limitingtractiveand
g
brakingforcesare
decidedbycoefficient
of friction b/w tires and
offrictionb/wtiresand
roadsurfaces
braking
Tractive and
andbraking
forcesaddsbending
throughsuspension.
Inertiaforcesadds
additionalbending.

Asymmetric loading
Asymmetricloading
Resultswhenonewheelstrikesa
raisedobjectsordropsintoapit.
Resolvedasverticalandhorizontalloads.
Magnitudeofforcedependson
Magnitude of force depends on

Speedofvehicle
Suspensionstiffness
Wheel mass
Wheelmass
Bodymass

Appliedloadisashockwave
Whichhasverylesstimeduration
h hh
l
d
Hencethereisnochangeinvehiclespeed
Actsthroughthecenterofthewheel.

Raised
object`

Asymmetric loading
Asymmetricloading
Resolvedverticalforcecauses:
Additionalaxleload
VerticalinertialoadthroughCG
Torsionmoment

tomaintaindynamicequilibrium.
to
maintain dynamic equilibrium
Resolvedhorizontalforce
causes:
Bending
Bendinginx
in xzzplane
plane
Horizontalinertialoadthrough
CG
Momentaboutzaxis

tomaintaindynamicequilibrium.
Totalloadingisthe
superpositionofallfourloads.

Allowable stress
Allowablestress
Vehiclestructureisnotfullyrigid
y g
Internalresistanceorstressisinducedtobalance
externalforces
Stressshouldbekepttoacceptablelimits
StressduetostaticloadXdynamicfactoryieldstress
Shouldnotexceed67%ofyieldstress.
Should not exceed 67% of yield stress

Safetyfactoragainstyieldis1.5
Fatigueanalysisisneeded
g
y
Atplacesofstressconcentration
Eg.Suspensionmountingpoints,seatmounting
points.
points

Bending stiffness
Bendingstiffness
Important
Importantinstructuralstiffness
in structural stiffness
Sometimesstiffnessismoreimportantthan
strength
Determinedbyacceptablelimitsofdeflection
of the side frame door mechanisms.
ofthesideframedoormechanisms.
Excessivedeflectionwillnotshutdoorproperly

Localstiffnessoffloorisimportant
Local stiffness of floor is important
Stiffenedbyswagespressedintopanels
Secondmomentofareashouldbeincreased
Second moment of area should be increased

Bending stiffness
Bendingstiffness
Thin
Thinpanelsseparatedbyhoneycomb
panels separated by honeycomb
structurereducedvibration
Localstiffnesshastobeincreasedat:
Local stiffness has to be increased at:
Door
Bonnet
B
Suspensionattachpoints
Seatingmountingpoints
Achievedbyreinforcementplatesandbrackets.

Torsional stiffness
Torsionalstiffness
Allowabletorsionforamediumsizedcar:8000to10000N
m/deg
/
Measuredoverthewheelbase
Whentorsionstiffnessislow:
When torsion stiffness is low:
Structuremove upanddown and/orwhip
Whenparkedonunevengrounddoorsfailtoclose
Doorsfailtoclosewhilejackingifjackpointsareatacorner
Doors fail to close while jacking if jack points are at a corner

Torsionstiffnessisinfluencedbywindscreens
TSreducesby40%whenwindscreensremoved
O
Opentopcarshavepoortorsionalstiffness
h
i
l iff
Handlingbecomesverydifficultwhentorsionalstiffnessis
low.

Chassis types Ladderframes

Chassistypes
Ladder frames

Usedbyearlymotorcars
Earlycarsbodyframedidnot
contributemuchforvehicle
structure.

Cross
beam

Mostlymadeofwood whichhaslow
stiffness

Carriedallload(bendingand
torsion)
Advantages:
Canaccommodatelargevarietyof
body shapes and types
bodyshapesandtypes
Usedinflatplatforms,boxvans,
tankersanddetachablecontainers

Stillusedinlightcommercial
vehicleslikepickup.

Siderails

Chassis types Ladderframes

Chassistypes
Ladder frames

Siderailsfrequentlyhaveopen
channelsection
Openorclosedsectioncrossbeams
Goodbendingstrengthandstiffness
Flangescontributelargearea
momentofinertia.
Flangescarryhighstresslevels
O
Opensection:easyaccessforfixing
i
f fi i
bracketsandcomponents
Shearcenterisoffsetfromtheweb
Local twisting of side frame is
Localtwistingofsideframeis
avoided
Loadfromvehicleisappliedonweb
Avoidsholesinhighlystressesflanges
Avoids holes in highly stresses flanges

Verylowtorsionalstiffness.

Chassis types Ladderframes

Chassistypes
Ladder frames
Clockwisesideframebending

Torsionincrossmemberis
reactedbybendingofside
db b d
f d
frames
Bendingincrossframesare
reactedbytorsionofside
t db t i
f id
frames
Allmembersareloadedin
torsion
Opensectionsarereplaced
byclosedsectionsto
improve torsional stiffness
improvetorsionalstiffness
Strengthofjointsbecomescritical
Maxbendingoccursatjoints
Attachmentofbracketsbecomes
morecomplex
l

Anticlockwisecrossframetorsion

Chassis types cruciformframes

Chassistypes
cruciform frames

Cancarrytorsionalloads,no
elementsoftheframeis
subjectedtotorsionalmoment.
Madeoftwostraightbeams
Have only bending loads
Haveonlybendingloads
Hasgoodtorsionalstiffnesswhen
jointincenterissatisfactorily
designed
Maxbendingmomentoccursin
joint.
Combining ladder and cruciform
Combiningladderandcruciform
frameprovidesgoodbendingand
goodtorsionalstiffness
Cross beams at front and back at
Crossbeamsatfrontandbackat
suspensionpointsareusedto
carrylateralloads

Chassistypes Torquetubebackbone
frame
Backbone
Mainbackboneisaclosed
boxsection
Splayedbeamsatfrontand
rear extent to suspension
rearextenttosuspension
mountingpoints
Transversebeamsresist
lateral loads
lateralloads
Backboneframe:bending
andtorsion
Splayedbeams:bending
Transversebeams:tension
or compression
orcompression

Transverse
beam

Splayedbeams

Chassis types Spaceframes

Chassistypes
Space frames

Inallframestillnowlengthinone
dimensionisverylesscompared
totheothertwodimensions
h
h
di
i
Increasingdepthincreases
bendingstrength
Usedinracecars
Allplanesarefullytriangulated
Beamelementscarryeither
y
tensionorcompressiveloads.
Ringframesdependsonbending
ofelements
Windscreen,backlight
Enginecompartment,doors
Lowershearstiffness

Indiagonalbracedframes
stiffnessprovidedbydiagonal
element

Chassis types Integralstructures

Chassistypes
Integral structures

Moderncarsaremassproduced
Sh t t l
Sheetsteelpressingsandspotwelds
i
d
t ld
usedtoformanintegralstructure
Componentshavestructuraland
otherfunctions
Sid f
Sideframes+depth+roofgivesgood
d h
f i
d
bendingandtorsionalstiffness
Geometricallyverycomplicated
StressdistributionbyFEMonly
Stressdistributionisfunctionof
appliedloadsandrelativestiffness
betweencomponents
Advantages:

Stifferinbendingandtorsion
Lowerweight
Lesscost
Quiet operation
Quietoperation

StructuralanalysisbySimpleStructural
Surfaces(SSS)method
f
( )
h d

Manymethodstodetermine
loadsandstresses
Elementarymethodisbeam
method,FEMisadvanced
methodandSSSisintermediate
DevelopedbyPawlowski in1964
Determinesloadsinmain
structuralelements
Elementsareassumedtoberigid
initsplane
p
Cancarryloadsinitsplane
Tension,compression,shearand
bending

Loadsnormaltoplaneand
bendingoutofplaneisinvalid
andnotallowed

SSSmethod Analysisofsimplevan
(
(torsioncase)
)

SSSmethod Analysisofsimplevan
(
(torsioncase)
)
Tenstructural
componentsare
considered
Ifgeometryisknownand
If geometry is known and
axleloadsareknown,
edgeloads(Qs)canbe
d
determined.
d
Forafullyladenvanfront
axle load is lighter.
axleloadislighter.
BymomentbalanceRr
canbedetermined.
R'r
Rf
* tr = * tf
2
2

SSSmethod Analysisofsimplevan
(
(torsioncase)
)

TheequilibriumofSSS2andSSS
3 are obtained by taking
3areobtainedbytaking
momentsasRf andRr areknown.

SSS2(frontcrossbeam)

P2w

SS 3 (Rear cross beam)

SS3(Rearcrossbeam)

P3w

Rf
* tf = 0
2
R'r
* tr = 0
2

P2andP3willbeequalin
magnitudeastheyactatthe
widthofthevehicleandthe
torque at the front and rear must
torqueatthefrontandrearmust
beequal.

SSSmethod Analysisofsimplevan
(
(torsioncase)
)
ConsideringSSS6
g
Q1 toQ5 willoccur
aroundperiphery
Appliesopposite
momenttoP2 andP3
TakingmomentatA
P 3(l1 + l 2 + l 3) Q 3(l1 + l 2 + l 3 + l 4) Q 4(h1 h 2) Q 2 h 2 P 2l1 = 0

ConsiderSSS4(frontpanel)
Q 6 h 2 Q1w = 0

ConsiderSSS5(reardoorframe)
Q 6 h1 Q 3 w = 0

SSSmethod Analysisofsimplevan
(
(torsioncase)
)

ConsiderSSS8(floorpanel)
Q 6(l1 + l 2 + l 3 + l 4) Q 2 w = 0

ConsiderSSS9(windscreenframe)
Q 6(h1 h 2)
Q5 w = 0
sin

ConsiderSSS
Consider SSS10
10(Roof)
(Roof)
Q 6l 5 Q 4 w = 0

SixunknownsQ1 toQ6
SubstituteQ2,Q3 andQ4
intheeqn ofSSS6
Q6 canbeobtainedand
b bt i d d
hencerestofthe
unknownscanbederived

SimpleStructuralSurfaces
representing a saloon car in
representingasalooncarin
bending
MaterialfromJ.H.Smith,2002

Passenger car
Passengercar
More
Morecomplexthanboxtypevan
complex than box type van
Detailedmodelvaryaccordingtomechanical
components
Frontsuspensionsloadsappliedtofrontwingas
for strut suspension
forstrutsuspension
Rearsuspension(trailingarmortwistbeam)loads
to inner longitudinal member under the boot floor
toinnerlongitudinalmemberunderthebootfloor
SSSsvarieswithbodytypes

Vehicle structures represented by SSS

VehiclestructuresrepresentedbySSS

Bus or box type vehicle

Busorboxtypevehicle

Van
Van

SSS andNotSSS

P
Passengercar

Structures that are structural surfaces

Structuresthatarestructuralsurfaces

ImagefromJ.C.Brown,2002

StructuresthatareNOTsimple
structuralsurfaces
l f

ImagefromJ.C.Brown,2002

Half saloon model

Halfsaloonmodel
Limitedto5Loads
Limited to 5 Loads
F1z=(radiator,bumper,battery)/2
F2z
2 =(engine)/2
= (engine)/2
F3z=onefrontpassengerandseat
F4z=onerearpassenger,seat,andhalffueltank
t
d h lf f l t k
F5z=(luggage)/2

1UDL(bodyweight)
(b
h)

Process
Process
Ca
Calculatereactionsatfrontandrearaxles
cu ate eact o s at o t a d ea a es
(takingmomentsandverticalforceequilibrium)
Rzf//2
Rrz/2

CalculateforcesineachoftheSSS
11equationswith11unknowns(K1, ..K10,M)
canbeevaluatedfromSSS1toSSS8
Equilibriumofrightframetobeverifiedwith
forcesandmoments

Half Saloon car model Bending

HalfSalooncarmodel

Figure

Transverse
TransverseSSS
SSS
representingthestrut
tower
ResolvingForces
K1 +K
+ K2 Rfzf /2
/ 2 =0
0

Moments
K1 =Rfz*w1/(
/(2*(w
( 1+w2))

SSS 1
SSS1

Figure

Upper
Upperfrontlongitudinal
front longitudinalSSS2
ResolvingForces
K1 K
K3 u(l
(l1 +l3)=0
) 0

Moments
K1l3 u*((l1+l3)2/2)M=0
/2) M =0

Figure

SSS3
Lowerfrontlongitudinal
Lower front longitudinal
ResolvingForces
F1z +FF2z +K
K5 K2 K4 =0
0

Figure

SSS4
engine
enginefirewall
fire wall
ResolvingForcesandby
symmetry
y
y
K5 K6 =0

Figure

SSS 5
SSS5

FloorCrossbeam(Front)
Floor Cross beam (Front)
Resolvingforcesandbysymmetry
K7K
K4FF3z =0

Figure

SSS 6
SSS6

Longitudinalunderboot
Resolvingforces
K9+K8 Rrz /2+F5z=0
Moments:
K9 =(Rrz*l6/2 F5l10)/(l5+l6)

Figure

SSS 7
SSS7

Floorcrossbeam(rear)
Floor cross beam (rear)
Resolvingforcesandbysymmetry
K9K
K11FF4z =0

Figure

SSS 8
SSS8
Rear
RearPanel
Panel
Resolvingforcesandby
symmetry
y
y
K10K8 =0

Figure

SSS 9
SSS9

Righthandsideframe
Resolvingforces
Resolving forces
K6 K7 +K11 +K10 u*(L+l6 l3)=0

MomentsaboutA
Moments about A
K10*(L+l6 l3)+K11*(L l3 l5)K7*(l4 l3)u*(L+l6 l3)2/2=0

Conclusion
SSSs
SSSs1to9aresubjecttoloads
1 to 9 are subject to loads
Therearboottopframe,rearscreen,roof,
windscreen floor panel and boot floor have
windscreen,floorpanelandbootfloorhave
noloadsappliedtothem
Thesideframe
Th id f
carriesthemajorloadsandis
i h
j l d
di
themainstructuralmember fordetermining
thebendingstiffness
h b di
iff
andstrength
d
h ofthecar.
f h

SSSrepresentationofasalooncarin
torsion
Front
Frontaxleisassumedto
axle is assumed to
belighterthanrear.
Maximumtorquethat
q
canbeappliedis:
Rfz
R ' rz
* tf =
* tr
2
2

Rfz andRrz arereaction

loadsatsuspension
mountingpoints
Rrz canbeobtained.

SSS1(Struttower)
The
Thecar'salignmentandstructural
ar's ali nment and str t ral
rigiditydependsonthestruttower.

Resolvingforces:
Forcesarenotbalanced.

Rfz
P1+P2 =0
2

Momentbalance

Takingmomentaboutthemedial
edge

P1 =

Rfzf
w2
*
2 (w2 +w1)

P1andP
and P2 canbedeterminedfrom
can be determined from
theaboveequations.
Asthisisahalfmodel,loadsonthe
leftstruttower(SSS1)willbe
equalbutoppositeindirection
lb
i i di
i

 SSS2(Upperfrontlongitudinal)

LoadP1 fromstruttoweristransmitted.

Forcebalance
P3 P1 = 0
Momentbalance
P1 isequaltoP3
createsamomentin
clockwisedirection
momentM
moment Mbalances
balances
Momenttakenwrt rear
edge
g

M'Pl1 3 =0

SSS2haveequalbutopposite
loads
loads.
P3andMcanbefound.

 SSS3(Lowerfrontlongitudinal)
P2 fromstruttoweristransmitted

Forcebalance:
P2 +P4 P5 =0
Momentbalance:
Takenwrt
k
rearedge
d

p2l4
P5 =
(l4 l5)

SSS3haveequaland
opposite loads
oppositeloads.
P4andP5canbe
found.

 SSS5(Floorcross
beam)

Momentbalance:

P4(tf 2w2) P7w=0

SSS6(Longitudinalunderbootfloor)
Forcebalance:

R ' rz
P9 + P8
=0
Momentbalance:2
R ' rz * l 6
P 6
9 willhaveequaland
=will have equal and
SSS
SSS6
2 * (l 6 + l 5)
oppositeloading
P7,P8 andP9 canbefound.

 SSS4(Enginefirewall)

Momentbalance:

P5(tf 2w2) Qh
1 1 Q2w= 0

SSS7(rearfloorcrossbeam)
Momentbalance:

SSS
SSS8
8
(
(rearfloorcrossbeam)
fl
b
)
Pt9 r Qh
1 2 Qw
3 =0
Momentbalance:

SSS10(rearfloorcrossbeam)
P 8 tMomentbalance:
r Q 1( h 3 h 2 ) Q 4 w = 0

Q 1( h h 1)
Q 6w = 0
cos

 SSS12(Roofpanel)

Momentbalance:

Ql1 8 Q7w=0

SSS13(Backlightframe)
Momentbalance:

QSSS14
SSS
14h (Trunktopframe)
(T
f
)
1( h
3) k t
Q 8w =
cos
Momentbalance:

SSS15(rearfloorcrossbeam)
Momentbalance:
Ql1 7 Qw
9 =0

Q 1( l 5

l 6) Q

10

w = 0

 SSS16(Mainfloor)

Momentbalance:

Q1 (SSS11
L l 5 SSS16arein
l 3) Q 11w = 0

complimentaryshear
SSS9(sideframe)
MomentaboutA:

Q4(L+l6 l3) +Q3(Ll5 l3) +P7(l4 l3)

+M'+Q6(l9cos) Q7(hh1)
11equationsand11unknowns
11 equations and 11 unknowns
Qcoc
8 Q..Q
(L+11l6.Canbesolved.
l7 l3) Q8sin(h3 h1)
1
Q9(h3 h1) Q10(h1h2) Q11(h1) =0

 Examinationoffigurereveals:
Shearforceisappliedtoallpanels
Includingwindscreenframe,backlight
g
,
g
frame,trunkframe,rearpanel,floor
panelandtrunkfloorpanel
Shouldhavegoodshearstiffness
Floorpanelrequiresswagingto
preventbuckling.
Windscreenframeandbacklightframe
must be constructed with stiff corner
mustbeconstructedwithstiffcorner
joints
Thisensuresshearistransferredto
roof.
Inotherwordstheseframesmustnot
shear.
Asinglepoorframestiffnesswillresult
in poor vehicle torsional stiffness
inpoorvehicletorsional

 Examinationoffigurereveals:
Windscreenframeandbacklightframe
arestiffenedbyglass,whichactsas
shear panel
shearpanel
Glassesarebondedtoframes
Thisensuresglassisretainedinfrontal
impacts
p
Glassissubjectedtoshearstress
Ifsurroundingframesarelessstiff
glassmaycrack
Rearpanelandtrunktopframeare
subjectedtoshear.
These2componentsarenotvery
good SSSs due to large discontinuity
goodSSSsduetolargediscontinuity
causedbytrunklid.
Overcomebyhighsillorliftover
Thismakespooraccessforloading
luggage

 Examinationoffigurereveals:
Siderearpanelswhichhousesrear
lightsaremadewidelikethesidesof
thetrunktopframe.
Abetterstructurewillincorporatea
panelorcrossbraceintheplaneof
rear sear back
rearsearback.
Mostofthemoderncardonothave
thisascustomerspreferfoldingseats.

Computational methods
Computationalmethods

Structuralanalysisisnowfundamentalin
vehicle design process
vehicledesignprocess
Finiteelementmethod(FEM)isa
promisingtoolinstructuralanalysis
Vehiclestructuresaredividedintosmall
elements
FiniteelementsdeformswhileinSSS
structuresareassumedtoberigid
Staticand/ordynamicequilibrium
equations along with material constitutive
equationsalongwithmaterialconstitutive
equationsaresolvedusinglinearalgebra
ComplexityofFEMincreasedasdetailof
vehiclemodelincreases
Beam elements represent sills window
Beamelementsrepresentsills,window
pillars,enginerailsandfloorcrossbeams
Floor,roof,bulkheadscanbemodeledby
equivalentbeamsthathavestiffness
equivalent to shear panels
equivalenttoshearpanels

Computational methods
Computationalmethods
Recentmodelsuseplate
andshellelementsto
d h ll l
accuratelyrepresentsheet
metalcomponents
Numberofloadsand
N b
fl d
d
numberofelementsresults
inaverylargedataset.
Longmodelpreparation
Long model preparation
timeandlongcomputer
solvingtime
InitialloadingtoFEMcanbe
Initial loading to FEM can be
derivedusingrigidbody
methodslikeSSS.