Introduction to Automotive industry

Classification Of Vehicles

Classification common to Body/ frame

Type of drive Engine type
consumers construction

Seat
arrangement Body Shape Number of
doors

Sedan

Lift back /
Hatch back

• Aero dynamics is the

Convertibles
common feature for all the
vehicles regardless of type
Station wagon of vehicle.
Pick-ups

Vans

Sport utility
Vehicles (SUV’s)
Sedan :
Vehicle with front and rear seats that
accommodates four to six persons.
It is classified as 2 or 4 door, 2-door
sedan is called coupe.

Hatch back :
Has a rear luggage
compartment, which is
an extension of
passenger compartment,
access to the luggage
compartment is gained
by upward opening of
hatch back door.
 Convertibles :
Have vinyl roofs, which can be raised
/lowered, available in two and four
models, those without rear seats called
sports car

Station wagon :
Characterized by its roof, roof extends straight
back allowing spacious luggage compartment

Pick-ups :
Have open cargo area behind driver’s
compartment.
Vans :
Has a tall roof and a totally enclosed large
cargo/passenger area (fig).

Sport utility Vehicles (SUV’s):

Described as multiple purpose vehicles
and carry wide range of passengers (fig).
 Substructures of
Automotive Vehicle

BIW Chassis Interiors Exteriors Electrical equipments Power Doors

and routings Train

Transmission &
Breaking
System
Substructures of Automotive Vehicle
 BIW - Body In White
An incomplete assembly of a vehicle generally consisting of all the major
panels welded together and prior to prime and paint processing
Nomenclature :
 A
Dash Header B
or pillar
cowl Joint

Shotgun

Cantrail
Front
side

B
Pillar

A
Radiator Pillar
support
Sill
Bumper
 BIW Body Construction
• Unitized construction
• Compact construction.
• Protects the occupants during collision.
• Energy gets transferred throughout the body when collides.
• Body over frame construction
• Frame should hold all the major parts and collide.
• Rubber mounts are used between body and frame to reduce the noise
and vibration.
• Only local damage occurs.

Objectives of Structural Design

• To make best use of material by arranging for each member to support as
near as possible to its maximum load potential.
• To make structure direct and continuous by providing an unbroken path
from the point of application to point of reaction.
 Typical Material
Thickness

S No Parts Thickness

1 Large area panels - Roof, Floor, 0.915 mm

Doors and Quarter panels.

2 Large area panels (curved contours ) 0.66 – 0.765 mm

3 Major structures- Cross members, 1 – 1.25 mm

Sills, Rails and Pillars.

4 Local reinforcements 1.625 mm

 Spot Welding Details
SWG Thickness Spot Weld Dia Average Shear Failing
(mm) (mm) Load (tonne)
20 0.915 4.575 0.64

18 1.22 5.6 0.813

16 1.62 6.35 0.895

Pitch for Spot welding

• Varies from 25.4 mm to 63.6 mm.

– According to minimum strength and sealing requirements.
– Minimum pitch = 3 x spot weld diameter.
 Three Zones of Body

• Crumble zone - Front

• Crushproof cell / Passenger compartment
• Crumble zone - Rear
Front Crumple Zone Rear Crumple Zone
• Fenders • Rear fenders
• Spring towers • Deck lid
• Dash Panel • Rear bumper / Fascia
• Bulk Head • Wheel arches
• Wheel arches
• Deck lids
• Front Bumper / Fascia
• Radiator panel grill • Rear floor panel extension
• Hood / Bonnet - inner / outer
• Front windshield
Crush Proof / Passenger Compartment
Floor front panel
Floor center (containing tunnel)
Floor extension panel
A pillar inner / outer
Side sill – box type (inner/ outer)
Cant Rail
BC pillar in/out
Door panel inner / outer
Seat mounting panels
Rear seat panel
Dash board mounting channels
Instrument Panel
Roof panel
Gutter
Rear windshield
Pre Style Feasibility
• Layout considering Ergonomics
• Seating Layout
• Layout for checking Driver’s Field of Vision, Windshield
• Wiping Pattern
• Defining the Vehicle Interior Envelope
Design for End use
• Reliability
• Aesthetics
• Economics
• Assembly
Design for Function
• Occupant comfort
• Occupant entrance and exit
• Travel
Occupant Space Design
Design For Safety
• Vehicle stability
• Acceleration and braking
• Vehicle controls
• Illumination
• Accidents Design for Crash
• Exterior surfaces
• Front, rear, side and roof crash
• Restraint system
• Door locks
• Interior surfaces
• Windshield
• Fire hazards
Design For Economy
• Minimum weight
• Fuel efficiency
• Wear
• Life
• Economic running
Load Path in a Typical Car
Body Construction
• Fastening methods
• Snap fit
• Spring clips
• Specialized fastening systems
• Threaded fasteners
• Riveting systems
• Welding
• Spot welding
• Arc welding
• Projection, stud and seam welding
• Adhesive bonding
• Mechanical bonding
• Welding ceramics and composites
Press working operations
• Cutting and forming
• Shearing and folding.
• Gas, plasma, laser and water jet
• Flame and jet cutting
• Press forming modes
• Shallow forming
• Deep drawing
• Super plastic forming
• Press braking
• Roll forming
• Flex forming
• Spinning and flow forming
 Detailed Design

• 3D Model & detailed 2D drawings of individual component's

showing stiffeners, beads, swages etc.

• Sheet metal stamping requirements addressed for all the

components.

• Detailed Assembly Sequence for the BIW.

• Locator scheme for each component/Sub Asbly/Asbly.

• Detailed assembly drawings with complete Weld details.

• Design modifications & verifications using CAE tools.

 BIW - CAE

System level Analysis Type

Modal analysis of BIW and trimmed
body Modal
Stiffness analysis of BIW (bending and
torsional stiffness) Linear static
Durability analysis of BIW Linear static
Point mobility analysis of body mounts
using BIW Dynamic
Reinforcing the BIW pillars for door
related requirements like door sag, door Linear static/
over opening. Nonlinear
Chassis
Chassis is the vehicle’s main support structure, also known as the ‘Frame.’ It
bears all the stresses on the vehicle in both static and dynamic conditions

Types of Chassis
• Ladder Chassis
• Backbone Chassis
• Monocoque Chassis
• Tubular Chassis
Ladder Frame Chassis

Ladder chassis gets its name, like a ladder. It has two long and heavy beams which are
supported by two short beams.

Advantages
•Easier to assemble as parts can be easily put in.
•Construction method makes it quite tough.
•Easier to fix as parts are not permanently attached.

Disadvantages
• Weak torsional rigidity making it bad for cornering.
• Heavyweight makes it not ideal for sports cars or hatchbacks.
Backbone Chassis

A rectangular cross-section cylindrical tube through the middle of the chassis that connects the top
and the bottom suspension

Advantages
•Half axle has contact with the ground when off-roading.
•The driveshaft is covered by the chassis makes it more likely to survive off-roading.
•The structure has good torsional rigidity allowing it to withstand more twist than ladder chassis.

Disadvantages
•The driveshaft repair is complicated if it fails as the main chassis covers the entire shaft which
makes it necessary to open it.
•The manufacture of backbone chassis is quite expensive which increases the cost of cars it is in.
Monocoque Chassis

A unibody structure, it too gets its name from its structural look. It took quite some time to figure out that
they can be used in cars as well because it is earlier used in aero planes. A monocoque is a shell around
the car made by using both chassis as the frame in a single construction. This is the most commonly
used chassis right now

Advantages
• It’s safer than both the other chassis due to its cage-like construction.
•The chassis is easy to repair as well.
•It has superior torsional rigidity.

Disadvantages
•The chassis is obviously heavy as it’s both the frame and chassis as one single entity.
•Producing it in small quantities is not financially feasible and thus it cannot be used for cars that are not
mass-produced.
Tubular Chassis

Tubular chassis were mainly used in race cars due to the unrivalled safety they provide. These were
stronger than ladder chassis. They employed the use of a strong structure below the doors to get more
overall strength. Tubular chassis are rarely used on passenger cars

Advantages
• Better rigidity compared to other chassis in the same weight.
• Offers the best weight/rigidity ratio allowing the car to be lightweight while being strong.
• Best choice for race cars due to lightweight and better rigidity than other chassis.
Disadvantages
• Tubular chassis are complex structures and cannot be made using autonomous methods.
• Tubular chassis are time-consuming to build and cannot be mass-produced.
• Not feasible to be used on passenger cars.
• The structure raises the door which makes it difficult to access the cabin.
AUTOMOTIVE INTERIORS (Refer Annexure 1 PPT)
Classification of Polymers:
➢ Natural and Synthetic Polymers.

➢ Organic and Inorganic Polymers.

➢ Plastics, Elastomers, Fibers and Liquid resins.

➢ Thermoplastic and Thermosetting Polymers.

•Thermoplastics : Heat softening/ Undergoes physical change, Melt on heating and solidify on
cooling - any number of times.

•
•Thermosets : Heat hardening/ Undergoes chemical change, Initially a liquid or a semisolid or
a powder, which solidify on heating for first time(by a polymerization chemical reaction),
•
✓ Phenol - formaldehyde
✓ Amino Plastics
✓ Epoxy resins
✓ Polyurethane
✓
Some important plastics that we should know:

Commodity plastics:
Engineering Plastics:
•Polyethylene terephalate.
•Olefins
Polyethylene. •Polybutylene terephalate
Polypropylene.
•Poly amides
•Vinyl group
Poly vinyl chloride. •Poly carbonate
•Styrene based plastics Specialty plastics:
General purpose polystyrene.
High impact polystyrene. •Polytetra fluoroethylene
Acrylonitrile butadiene styrene.
Styrene acrylonitrile. •Polyphenylene sulphide

•Acrylic group •Polyether etherketone

Polymethyl methacrylate.
•Liquid crystal polymers
Plastic Blends
Blends are mechanical mixtures of chemically different polymers or co- polymers.

Expectations of Blends
•High performance at reasonable price.
•Modification of performance as market develops.
•Extending the performance of expensive resins.
•Generation of unique materials.
•They should be economical, competitive and should not affect other needed properties.
•They should be easy to process.

Most commonly used Blends:

•ABS/PVC Blends

•PC/ABS Blends

•PBT/PC Blends

•EPDM/PP
 PLASTICS
➢ ADVANTAGES.
• Light Weight
• High Strength-to-Weight Ratio
• Complex Parts - Net Shape
• Variety of Colors (or Clear)
• Corrosion Resistant
• Electrical Insulation
• Thermal Insulation
• High Damping Coefficient
• “Low” pressures and temp required
•
•
➢ DISADVANTAGES.
• Creep
• Thermally Unstable
• U-V Light Sensitive
• Relatively low stiffness
• Relatively low strength
• Difficult to Repair/Rework
• Difficult to Sort/Recycle
PLASTIC MANUFRACTRING PROCESSES
➢ Extrusion.
➢ Thermoforming.
➢ Lamination (Calendaring)
The thermal solidification of thermosets leads to Processing methods
➢ Casting
such as
➢ Molding.
▪ Transfer Molding ➢ Hot compression molding.
▪ Blow Molding
▪ Compression Molding
▪ Rotational Molding
▪ Reaction Injection Molding
▪ Injection Molding

➢ Expansion
➢ Foaming
Less Common Used processes
➢ Spinning
➢ Solid Phase Form
Extrusion
Extrusion process
• most common manufacturing of plastic resin
• combines pigments, additives and resin
• high heat, high pressure ➔ molten mixture
• pushed through die
• create warm plastic for possible further “finishing”
operation such as pelletizing, calendaring, or molding

Figure ref: Process Selection, KG Swift and JD Booker, p. 64.

Thermoforming

Typical parts: advertising signs, refrigerator liners, packaging,

appliance housings, panels for shower stall.

Ref: Figure from S. Kalpakjian, Manufacturing Processes for Engineering Materials, Second Ed., Addison Wesley, 1991
Calendaring

Ref: Figure from: S. Kalpakjian, Manufacturing Processes for Engineering Materials, Second Ed., Addison Wesley, 1991
Casting

Ref: Figure from: S. Kalpakjian, Manufacturing Processes for Engineering Materials, Second Ed., Addison Wesley, 1991
Molding
Molding process
• Most common plastic “finishing” process
• Many molding methods
– Transfer Molding
– Blow Molding
– Compression Molding
– Rotational Molding
– Reaction Injection Molding
– Injection Molding
Transfer Molding

Typical parts: electrical and electronic components, rubber and silicone parts.

Ref: Figure from: S. Kalpakjian, Manufacturing Processes for Engineering Materials, Second Ed., Addison Wesley, 1991
Blow Molding, Bottles

• Hollow plastic parts with relatively thin walls.

• Typical parts: Bottles, Bumpers, Bags, Ducting.

Figure ref: Process Selection, KG Swift and JD Booker, p.55.

Compression Molding
• Pre-shaped part placed directly into
heated mold.
• Examples: Dishes, Handles, Electrical
Components, Fittings and housings

Figure ref: Process Selection, KG Swift and JD Booker, p. 50.

Rotation Molding

Typical parts: tanks, trash

cans, boat hulls, buckets,
housings, toys, carrying cases,
and footballs.

Ref: Figure from: S. Kalpakjian, Manufacturing Processes for Engineering Materials, Second Ed., Addison Wesley, 1991
Injection Molding
• Complex Plastic Parts
• Examples: Fittings, Containers, Bottle
Tops, Housings

Schematic of thermoplastic Injection molding machine

Figure ref: Process Selection, KG Swift and JD Booker, p. 46.
Reaction Injection Molding

Typical parts: automotive bumpers and

fenders, thermal insulation for
refrigerators and freezers, and stiffeners
for structural components.

Ref: Figure from: S. Kalpakjian, Manufacturing Processes for Engineering Materials, Second Ed., Addison Wesley, 1991
 PLASTIC PRODUCT DESIGN
The Five Design rules
Rule 1 : Use uniform wall thicknesses throughout the part. This will
minimize sinking, warping, residual stresses, and improve mold fill and
cycle times.

When uniform walls are not possible (due to design limitation), then the change in section should
be as gradual as possible

Poor Design Improved

Design
Rule 2 : Use generous radius at all corners to avoid part failure,
stress concentrations and poor flow patterns.
Indicate radii at all inside corners to the maximum which a design will
allow. The outside radius should be equal to the inside radius plus the
wall thickness.
Outer radius(R) = Inner radius(r) +thickness(t)

• A fillet radius(r) should be between 25% to 60% the nominal wall

thickness or a minimum radius of 0.02 inch (0.5mm) is suggested.

• The larger fillet radius suggested for load carrying features.

• Break any sharp corner with at least 0.005 inch (0.13mm) radius.
Rule 3 : Design parts to facilitate easy withdrawal from the
mold by providing Draft (taper) in the direction of mold
opening or closing.
Drafts & Parting line
➢ Drafts (or taper) in a mold, facilitates part removal from the mold.
The amount of draft angle depends on the depth of the part in the
mold, and its required end use function.
➢ On the surface in the direction of mold opening or closing a
minimum of 1/20 to be specified.
➢ Typically draft angle is 10 with 1/20 on ribs.
➢ Where minimum draft is desired due to design limitations, good
polishing. recommended and depth should not exceed 0.5 in.
➢ More draft aids ejection but may generate a material mass on
sections contained in one side of the mold.
➢ The mold parting line can be relocated to split the draft in order to
minimize it.
 Rule 4 : Use ribs to improve part stiffness in bending. This avoids the
use of thick section to achieve the same, thereby saving on part weight,
material costs, and cycle time costs.
coring

Ribbing

Gusset

• At rib intersections, Coring should be

provided to thin down the walls to avoid
excessive sinking on the opposite side
Rib thickness (W) should be less than wall thickness to minimize sinking
Thk. (W) Range = 40-60% of ‘t’

Height h = 3 to 5 times of ‘t’

Draft = 0.50 to 1.50

r = 20% to 50% of ‘t’

Spacing between parallel lines (a) = 2x‘t’ min.

This spacing keeps the mold from developing a hot blade and cooling
problems
 Rule 5 : Provide Bosses and
Gussets

Bosses are used for the purpose of registration of

mating parts or for attaching fasteners such as
screws or accepting threaded inserts (molded-in,
press-fitted, ultrasonically or thermally inserted).

d R

• Typically Bass OD (D) = 2 X ID(d)

•Boss height should be less than 3 X OD
Boss
➢ Boss should not be placed next to a
parallel wall; instead, offset the boss
and use gussets to strengthen it.
Gussets can be used to support bosses
that are away from the walls.

➢ The same design rules that apply for

ribs also apply for gussets.
PLASTIC MOULD DEFECTS
SHEET METAL OPERATIONS
Sheet Metal Operation : BENDING

Types of bending

1.Edge bending
2.V-bending
3.U-bending
4.Offset bending
5.Channel bending
Types of BENDING

U Bending
Sheet Metal Operation : SHEARING
It is a cut in a straight line across a strip, sheet or bar. In this operation, a sheet
metal workpiece is placed or kept between two dies from one end. And, the
punch is hit at the other end of the sheet, producing a shearing effect.

Effects during shearing operation

1.Plastic deformation
2.Fracture
3.Shear
Sheet Metal Operation : BLANKING
Blanking is the process of producing flat pieces from sheet metal. Only a small amount of
sheet metal will be processed as a finished product or part over the larger sheet area in the
blanking process.
Sheet Metal Operation : PUNCHING
The punching operation is vice versa to blanking. In this operation, extra (scrape) material
removes from the raw sheet. This operation also performed with the help of die and punch.
But here the punch removes scrap
Sheet Metal Operation : TRIMMING & SHAVING
Trimming is the removal of excess metal from a stamped part to give a finished
product

Shaving is a secondary process that can be used to improve edges of cuts that have
already been made
Sheet Metal Operation : PARTING
Parting involves cutting a sheet metal strip by a punch with two cutting edges that
match the opposite sides of the blank
Sheet Metal Operation : SLITING
Sheet Metal Operation : LANCING
Lancing is a process in a metal sheet in which metal is cutting a sheet of metal through
part of its length and then bending the cut portion
Sheet Metal Operation : NOTCHING
Notching operation is to cut out a portion of the sheet from its sides. And in semi notching
operation metal cutting out from inside of the sheet. Sometimes, notches applied for stress
relieving during the bending.
Sheet Metal Operation : PERFORATING
Perforating is an operation to punch to create different holes sizes, shapes
and patterns
Sheet Metal Operation : NIBBLING
Sheet metal nibbling is a technique, that involves punching out holes so they
overlap to produce all types of irregular contours or shapes.
Sheet Metal Operation : EMBOSSING
Sheet metal embossing is a stamping process for producing raised or sunken
designs or relief in sheet metal. This process can be made by means of
matched male and female roller dies, or by passing sheet or a strip of metal
between rolls of the desired pattern

Embossed Restored
Sheet Sheet
Sheet Metal Operation : CUTOFF
This operation separates the work material along a curve (which may be a straight line or
irregular single curve). That’s why in the Cut-off operation no scrape will be created. For
example, cutting a paper into two pieces using a seize
Sheet Metal Operation : COINING
Coining is a form of precision stamping in which a work-piece is subjected to a
sufficiently high stress to induce plastic flow on the surface of the material.
Sheet Metal Operation : DEEP DRAWING
Deep drawing is a process of converting metal sheet into cylindrical or box shaped
structure with or without changing its length and thickness. Many cylindrical parts like
metal can, pots, container for food and beverages, kitchen sinks, automobile fuel tank etc.
are deep drawing product
Sheet Metal Operation : STRETCH FORMING
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 contoured parts.
Sheet Metal Operation : ROLL FORMING
Roll forming is a continuous process which converts sheet metal into an engineered shape
using consecutive sets of mated rolls, each of which makes only incremental changes in
the form.
FRONT DOOR
Sail panel
Front Door glass
Remote
handle
Switch
Inner sheet bezel
metal panel
Speaker
Upper door
substrate Map pocket
Bolster Arm rest
Lower door
substrate
EXPLODED VIEW OF FRONT DOOR Upper door
substrate
Upper door
skin
Upper foam
block Bolster
substrate
Bolster
skin
Outer sheet
5-Gang
metal panel
Switch
Arm rest skin
Arm rest substrate
Lower foam block
 Structural Tests
SIDE, FRONTAL, POLE IMPACT TESTS - VIDEOS
 Structural Tests

300N door opening

direction

Vertical
Door Frame
stiffness
 Structural Tests
300 N
300 N

500 N in
the latch
Test 1: Vertical stiffness Test 2: Door Frame Front Test 3: Door Frame Rear

50 N 50 N 470 N

Test 4: Compression Test 5: Traction Test 6: Aerodynamic load

 Door Trim Module Description

Sealing system:
- Sealing joint all around the door trim panel.
- Every mobile piece has a seal joint.
- The sealing concept is validated and in the market.

Sealing joint all

around the door trim
 Door Trim Module Description

Medallion:
- Low pressure injection technology.
- Cover with fabric.
- Integration of the clip’s in the medallion part.
 Door Trim Module Description

Door trim support:

Integrated clip’s for

the harnesses

Loudspeaker
cover Latch
support
 Door Trim Module Description

Door trim support:

Integrated
fixing system
for the door
trim

Fixation for the

window lifter
motor

Reinforcement in
the middle part of
the door trim Plastic
padding Door sheet
metal
 Door Module Experience
Renault Megane Platform
Sealing

Latch

Loudspeaker

Exterior Handle
Window
regulator
 Door Module Experience
Renault Megane Platform
Sealing

Latch

Exterior
Handle
Loudspeaker

Side Impact
Bolster

Window Regulator
 Electrical Accessories
Every automobile is equipped with a number of electrical instruments and accessories to
provide the driver more comfort and safety.
Windshield wiper/ washer systems
Windshield washers
Windshield wiper linkage and blades
Lift gate wiper/ wiper system
Power door lock systems
Power trunk release
Power windows
Power seats
Power lumbar supports
Heated seats
Memory seats
Adaptive seating
Power mirror system
Rear and front window defrosters and heated mirror system
Horn And Horn Relay
Cruise control system
Transducer
Servo unit
Composite:
Halogen headlights that have replaceable bulbs are called composite headlights.

High Intensity Discharge (HID)

Headlamp switch
Dimmer switches
Automatic headlamp controls
Turn lights
Stop lights
Back Up Lights
Auxiliary lights
Driving lights
Fog lights
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