Course Structure & Syllabus of III Year for the Academic Year 2021-22

AUTOMOBILE BODY DESIGN (2-2-0)

Sub Code: ME6E117 CIE: 50 %
Hrs / Week: 04 SEE: 50 %
SEE Hrs: 2 Hrs Max. Marks: 50

Course outcomes:
Upon successful completion of this course, the student will be able to:
1. Identify customer requirements and commodities of Body in White (Baw) parts.
2. Understand various techniques in sheet metal forming and joining
process in automobile body design.
3. Comprehend the Design verification of BiW and validation
methods in FEA and CFD packages.
Course Content
Module – 1
Introduction to pre-program stages: Voice of customer, competitor insight, innovation, Project
and quality planning, legislation. Product life cycle and important gateways for BIW, Definition
of PLM, Flow chart of PLM, Product life cycle, Design milestones, Types of builds, Launch of
Vehicle,
Introduction to BIW: Identification of commodities for BIW, Closures, Body Shell, BIW
terminology, BIW Assembly, The Basic of design, meaning of design, its application and
principals of good design, automotive studio in detail and Class A Surfaces, their requirements
and usage. 9 Hrs.
SLE: Case study on customer requirement

Module 2:

BiW and Sheet Metal: Sheet Metal Formability, stages in sheet metal manufacturing, types of
draw dies, draw model development in CAD Software, forming simulations, and sheet metal die
design & elements used in the die and its functions

Bonnet design case study: Function of Bonnet, Defined Input to Bonnet, Intended Input to
Bonnet Design, Steps in Bonnet design. 8 Hrs.

SLE: Case study on bonnet design

Module 3:
CAE methods for Design verification of BIW: Structural Analysis, Fatigue life Prediction, Noise
and vibration, Crash Impact analysis, Multibody Dynamics, Thermal analysis, CFD. Verification
and Validation with respect to FEA

Department of Mechanical Engineering, NIE, Mysore Page 79

 Course Structure & Syllabus of III Year for the Academic Year 2021-22

CAE Analysis - NVH, Crash & Durability: Concept of CAE & FEA. NVH Analysis, Load cases
for NVH analysis: Static Bending stiffness, Static torsion stiffness, Natural frequency and normal
modes, Crashworthiness 9 Hrs

SLE: case study on CAE analysis

Crash Analysis case study: Tutorial Component

1. Full vehicle level: Frontal, Side and rear Impact,
2. Component Level: Seating and roof crush,
3. Durability analysis: Various load cases like Front and Rear Recovery analysis,
Trailed towing analysis, Luggage retention hook analysis, Floor pan fatigue,
Roof and Body side oil canning, Vehicle jacking analysis, Vehicle hoisting
analysis, Fatigue analysis of BIW.
4. Use of modelling software (solid works / Catia) for preparing the model relevant
to Automobile body
5. Using FEA package (ANSYS) for performing Structural, Model and Crash
analysis on simple Automobile components. 26 Hrs

Text Book:
1. The Automotive Body: Volume I: Components Design: by Lorenzo
Morello & Lorenzo Rosti Rossini & Giuseppe Pia & Andrea Tonoli
(auth.), Springer
2. An Introduction to Modern Vehicle Design, Edited by Julian Happian-Smith,
3. How To Design Car Like A Pro, by Tony Lewin , Ryan Borroff , Ian Callum
Evaluation Pattern:
1. Written Tests (Test 1, 2 & 3) are evaluated for 20 Marks each out of
which sum of best two for 40 marks are taken.
2. Assessment in practical classes: 10 marks

Mapping of COs to POs and PSOs:

Course Outcomes Programme Outcomes Programme Specific Outcomes

CO1 PO1, PO4 &PO5 PSO1, PSO3
CO2 PO1, PO4 &PO5 PSO1, PSO3
CO3 PO1, PO4 &PO5 PSO1, PSO3

Department of Mechanical Engineering, NIE, Mysore Page 80