Introduction to modern

automotive design
Le Van Nghia, PhD
Faculty of Transportation Engineering

Email: [Link]@[Link]
MODERN AUTOMOTIVE DESIGN

• COURSE DESCRIPTION
This course provides the general knowledge of automotive design with method and process
design of its constituent parts. Students are provided with knowledge to perform analysis
structure characteristics, requirements and conditions of work of each department in the car
in order to select the method in design, identify basic structural parameters, design parts
and evaluate their quality and durability.

GOALS:
- Analyze the working conditions of the cluster (system) to determine the load mode
and choose design options
- Apply the specialized knowledge needed to design computational clusters of
automotive systems
- Assess ability to work, quality and reliability of the cluster (system) design
- Understanding of design methods using 3D software

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Course Administration

• Suggested pre-requisites: Basic knowledge on

automotive structure, mechanical engineering.
• Instructor:
• Le Van Nghia, [Link]@[Link]
• Office hours : Monday-Fridays 2:00-4:00pm, Nha Khung
– Nha T
• Lectures: Week 27-34, 36-43; Class hour: Mo and
Th, Class hour 5-6 (AM), D6-302
• Textbook:
• Julian Happian-Smith, An Introduction to Modern Vehicle Design, 2002, 600p.
• Nguyễn Trọng Hoan, Bài giảng thiết kế tính toán ô tô

3
Course Administration

• Other References:
1. Automotive Power Transmission Systems. Yi Zhang, Chris Mi, 2018 WILEY-VCH Verlag
GmbH & Co. KGaA, 455p.
2. VEHICLE POWERTRAIN SYSTEMS, Behrooz Mashadi, David Crolla, WILEY 2012, 560p
3. Braking of Road Vehicles Andrew Day, ELSEVIER SCIENCE B.V., 2014, 473p.
4. Powertrain, Chassis System and Vehicle Body, Edited by David A. Crolla, ELSEVIER
SCIENCE B.V., 2009, 835p.
5. Automotive Engineering Fundamentals, Richard Stone, Jeffrey K. Ball,SAE Internationa/,
636p.
6. Clutches and Brakes Design and Selection Second Edition, William C. Orthwein, 2004
Marcel Dekker, 337p.

• Course Notes and Links: Slides and Notes at class.

• Grading: Attention, Class Project, Mid-term and
Final exams

4
Chapter 1 - General requirements
for automotive design
Le Van Nghia, PhD
Faculty of Transportation Engineering

Email: [Link]@[Link]
1. Automotive engineering development

• 1.1 Introduction
• 1.2 Innovations and inventions
• 1.3 Mass production
• 1.4 The development of the world motor industry
• 1.5 Streamlining
• 1.6 Commercial vehicles
• 1.7 Engine developments
• 1.8 Transmission system development

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1. Automotive engineering development

• 1.9 Steering
• 1.10 Suspension
• 1.11 Brakes
• 1.12 Interior refinement
• 1.13 Safety design
• 1.14 Too much innovation
• 1.15 References and further reading

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References and further reading

• Books on motoring are numerous, but unfortunately,

they only seem to stay in print for a relatively short
time. Wherever possible, we have tried to select
books that should be readily available in a good
academic library. The remainder should be
obtainable on the inter-library loan system.
• Barnard, R.H. (1996). Road Vehicle Aerodynamic
Design. Longman. A description of the basic principles
of the subject aimed particularly at undergraduate
engineers, with emphasis on the physical principles, and
with a minimum of mathematical content.

8
References and further reading

• Faith, N. (1995). Classic Trucks: Power on the Move

(accompanied the Television Channel Four series).
Boxtree (ISBN 0-7522-1021-1). A very readable text
which gives a good outline of the history of commercial
vehicles, with emphasis on developments in Britain.
• Ickx, J. (1992). ‘The Bollées’, in Barker, R. and
Harding, A. (eds.), Automobile Design: Twelve Great
Designers and their Work. SAE (ISBN 1-56091-210-
3). Describes in detail the achievements of some of the
great automotive designers from around the world. It
also traces the origins of many important innovations.

9
References and further reading

• Lord Montagu of Beaulieu and Sedgwick, M. (1960).

Lost Causes of Motoring, Cassell, London. An
excellent description of the rise and fall of all the
famous marques in British motoring history with an
analysis of the reasons for their demise. There are two
companion volumes: Lost Causes of Motoring –
Europe, volumes 1 and 2.
• Newton, K., Steeds, W. and Garrett, T.K. (1983). The
Motor Vehicle (10th edn). Butterworths (ISBN 0-
408-01118-1 (hard cover) and 0-408-01157-2 (soft
cover)). Detailed descriptions of the workings of
automotive components both current and historical.

10
References and further reading

• Womack, J.P., Jones, D.T. and Roos, D. (1990). The

Machine that Changed the World. Maxwell
Macmillan International. The result of a large-scale
research exercise, this book traces the development of
vehicle manufacturing systems and expounds the
advantages of the lean production system which
originated in Japan.
• Wood, J. (1998). Wheels of Misfortune: the Rise and
Fall of the British Motor Industry. Sidgwick and
Jackson, London (ISBN 0-283-99527-0). An analysis
of the reasons for the failure of the indigenous British
motor manufacturing industry.

11
Further reading

• ‘Automotive Milestones’. Automotive Engineering,

September 1996. Key dates for the introduction of
technical innovations in the USA, with other historical
articles.
• Howard, G. (1986) Automobile Aerodynamics.
Osprey (ISBN 0-850445-665-7). An illustrated history
of the subject of automobile aerodynamics.
• Pawlowski, J. (1969). Vehicle Body Engineering.
Business Books Ltd (ISBN 0-220-68916-4). A good
general description of the subject of automotive
engineering design with some historical material.
• Whyte, A. (1984) The Centenary of the Car,1885–
1985. Octopus Books (ISBN 0-7064-2006-3). A well-
illustrated general history.
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2. Modern materials and their incorporation into vehicle design

• 2.1 Introduction
• 2.2 Structure and manufacturing technology of
automotive materials
• 2.3 Mechanical and physical properties of
automotive materials
• 2.4 Materials selection for automotive components
• 2.5 Component materials case studies
• 2.6 References and further reading

13
References and further reading
• Adler, U. (1993). Automotive Handbook. Bosch (ISBN 1-56091-372-X).
• Ashby, M.F. and Jones, D.R.H. (1980/85). Engineering Materials, I/II. Pergamon (ISBN 0-08-012139-6 and
ISBN 0-08-032531-9).
• Atkinson, A.J. and Young, R.J. (1985). Fracture Behaviour of Polymers. Elsevier (ISBN 0-85334-7294-6).
• Bolton, W. (1989). Production Technology. Butterworth-Heinemann (ISBN 0-434-90186-3).
• BS 970, Part 3, 1991: ‘Bright Bar for General Engineering Purposes’.
• Brydson, J.A. (1985). Plastics Materials. Butterworth-Heinemann (ISBN 0-7506-1864-7).
• Callister, W.D. (1987). Materials Science and Engineering. John Wiley (ISBN 0-471-13459-X).
• Cebon, D. and Ashby, M.F. (1994). Cambridge Materials Selector (Software). Granta Design Ltd.
• Charles, J.A. et al. (1989). Selection and Use of Engineering Materials. Butterworth-Heinemann (ISBN 0-
7506-1549-4).
• Cottrell, A. (1985). Introduction to Metallurgy. Edward Arnold (ISBN 0-7506-1549-4).
• Doremus, A. (1991). Glass Science. John Wiley ( ISBN 0-471-89174-6).
• Hall, C. (1989). Polymer Materials. Macmillan (ISBN 0-333-46397-X).
• Harrison, A. (1997). Advanced Materials and Process Development. Ford Motor Company, Basildon,Essex,
UK.
• Institute of Materials, Materials Information Service, 1995, London, SW1Y 5DB
• Kalpakjian, S. (1991). Manufacturing Processes for Engineering Materials. Addison-Wesley (ISBN0-201-
11690-1).

14
References and further reading
• Kennedy, J. (1993). Adhesives in the Automotive Industry. Materials World, December 1993.
• Kingery, W.D. (1986). High Technology Ceramics. American Ceramics Society (ISBN 0-916094-88-X).
• Lenoe, E. et al. (1983) Ceramics for High Performance Applications III (ISBN 0-306-40736-1).
• Litchfield, A. (1995). The Aluminium Car. Aluminium Extruders Association, Birmingham, B15 1TN
• Mayer, R.M. (1993). Design with Reinforced Plastics. Design Council (ISBN 0-85072-294-2).
• Mills, N.J.(1986). Plastics. Edward Arnold (ISBN 0-7131-3565-4).
• Montgomery, D.C. (1991). Design and Analysis of Experiments. John Wiley (ISBN 0-471-52994-X).
• Ohring, M. (1995). Engineering Materials Science. Academic Press (ISBN 0-12-524995-0).
• Powell, P.C. (1983). Engineering with Polymers. Chapman & Hall (ISBN 0-412-24160-9).
• Sheldon, R.P. (1982). Composite Polymeric Materials. Applied Science (ISBN 0-85334-129-X).
• Shute, A. (1997). Lotus Engineering. Hethel, Norwich, UK.
• Smallman, R.E. (1985). Modern Physical Metallurgy. Butterworth-Heinemann.
• Smith, W.F. (1993). Fundamentals of Materials Science and Engineering. McGraw-Hill (ISBN 0-07-
059202-0).

15
References and further reading
• Somiya, S., Mitomo, M. and Yoshimura, M. (1989). Silicon Nitride. Elsevier (ISBN 1 85166 329 0).
• Timmings, R. and May, T. (1990). Mechanical Engineer’s Pocket Handbook. Newnes-Butterworth-
Heinemann (ISBN 0-7506-0919-2).
• Transformation Toughening: Part 4 – Fabrication, Fracture and Strength of Alumina-Zirconia Composites.
J. Mat. Sci, 17 (1982).
• Turner, S. (1983). Mechanical Testing of Plastics. Longman (ISBN 0-7114-5785-9).
• Walker, E. and Lowe, K.(1995). ‘Ultralight Auto Bodies’, Materials World, December 1995.
• Watson, M.N. (1988). Joining Plastics in Production. Welding Institute (ISBN 0-8530-0202-9).
• West, J.M. (1986). Basic Corrosion and Oxidation. Ellis Horwood-John Wiley (ISBN 0-85312-997-5).
• Williams, A.R. and Evans, M. (1995). ‘Tyre Technology’, Materials World, December 1995.

16
Further reading
• 1. Ashby, M.F. and Jones, DRH (1980/1985). Engineering Materials, I/II. These two volumes are set at
undergraduate level and provide a survey of each of the engineering materials with extensive illustrations
and basic data.
• 2. Cottrell, A. (1985). Introduction to Metallurgy. This is a standard text for undergraduate metallugists
and metallurgical engineers covering structure, processing, property relationships.
• 3. Brydson, J.A. (1995). Plastics Materials. This is a detailed reference book for plastics and other
polymeric materials dealing not only with structure, processing and property relationships but also with
polymer manufacture, design and commercial topics.
• 4. Kingery, W.D. (1986). High Technology Ceramics. This is a more recent collection of specific ceramics
topics based on a standard ceramic text, comparable with those of the Cottrel and Brydson.
• 5. Sheldon, R.P. (19982). Composite Polymeric Materials. This is a general composites book, set at post-
graduate level, based on the author’s experience in polymer physics.

17
3. The manufacturing challenge for automotive designers

• 3.1 Introduction
• 3.2 Lean product development and lean production
• 3.3 Design to manufacture as a single process and
IPPD
• 3.4 Manufacturing analysis, tools and methods
• 3.5 Materials processing and technology
• 3.6 Conclusions
• 3.7 Acronyms
• 3.8 References and further reading

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Further reading
• Bralla 1986 (see above list for reference). A comprehensive handbook of
manufacturing processes and materials. Provides clear and concise guidance for
the design of products for efficient and effective manufacture.
• SAE 1997. A collection of papers on value based techniques for automotive
engineering. Provides insight into value lessons learned and techniques for
matching the voice of the customer with the voice of the producer.
• Smith and Reinertsen, 1991. An examination of techniques to address the rapid
introduction of new products. Taking a management perspective and drawing
upon a wealth of experience, the authors provide a framework for an integrated
approach to product development.
• Usher, J., Roy, U. and Parsaei, H., eds. 1998. Integrated Product and Process
Developmen. New York:
• John Wiley and Sons, Inc. pp 151–183, ISBN 0-471-15597-7. Taking the DOD
definition and providing a valuable insight into the tools, techniques, and
philosophy of integrated product and process development. Provides practical
experience of IPPD application and suggests the way forward from concurrent
and systems engineering through the IPPD concept.

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General requirements for automotive design

1.1 Determination and classifications

1.2 General requirements for automotive design

1.3 Standards and Regulations

1.4 Automobiles Design and Manufacturing

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General requirements for automotive design

1.1 Determination and classifications

- What is automobile?
TCVN 6211: 2003 (ISO 3833 : 1977):

QCVN 09 : 2011/BGTVT: Dynamic requirements?

- Types of automobile? Classification?

TCVN 7271-2003

Classifications by weight : M,N,O

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Vehicle Classification

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 General requirements for automotive design

1.2 General requirements for automotive design

1. Using requirements
- Appearance - Handling

- Available space
- Safety
- Ergonomics

- Climatecomfort - Resistance to age

- Dynamiccomfort

- Dynamicperformance

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General requirements for automotive design

1.2 General requirements for automotive design

2. Technical requirements

- Parameters

- Measurement of these parameters

- Optimal value of parameters

- Quantity control of OEM parts

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 General requirements for automotive design

1.2 General requirements for automotive design

3. Design requirements
- Dynamic: maxspeed, fuel consumption, grade, acceleration

- Control and safety: lateral acceleration, sideslip, …

- Ergonomics: comfort

- Climatecomfort: temperature control

- Dynamiccomfort: acceleration

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General requirements for automotive design

1.3 Standards and Regulations

-USA: FMVSS (Federal Motor Vehicle Safety Standards);
-Canada: CMVSS (Canada Motor Vehicle Safety Standards);
-China: GB standards (Guobiao standards);
-Australia: ADR (Australian Design Rules);
-Japan: TRIAS (Test Requirements and Instructions for Automobile Standards );
-India: AIS (Automotive Industry Standards);

International standards:
-ECE(United Nations Economic Commission for Europe)
-EC–Directive: EU

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General requirements for automotive design

1.4 Automobiles Design and Manufacturing

Design

Make
Correction samples
3-5 years

Experiments
and testing Assembly

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General requirements for automotive design

EX1. Gearbox Design

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General requirements for automotive design

EX1. Gearbox Design

Calculation the
vehicle
dynamic

Gearbox
General
ratios
Design

Choose
options

Make
sketch

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General requirements for automotive design

EX1. Gearbox Design

gears

shafts

Parts
Design bearings

Shifting
mechanism

Shell, box

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General requirements for automotive design

EX1. Gearbox Design

gears

shafts

Parts
Design bearings

Shifting
mechanism

Shell, box

31
General requirements for automotive design

EX1. Gearbox Design

32
General requirements for automotive design

EX1. Gearbox Design

33
General requirements for automotive design

EX1. Gearbox Design

34
General requirements for automotive design

EX1. Gearbox Design

35
General requirements for automotive design

EX1. Gearbox Design

36
General requirements for automotive design

EX1. Gearbox Design

37
General requirements for automotive design

EX1. Gearbox Design

38
General requirements for automotive design

EX1. Gearbox Design

39
General requirements for automotive design

EX1. Gearbox Design

40
General requirements for automotive design

EX1. Gearbox Design

41
General requirements for automotive design

EX1. Gearbox Design

42
General requirements for automotive design

EX1. Gearbox Design

43
General requirements for automotive design

EX1. Gearbox Design

44
General requirements for automotive design

EX1. Gearbox Design

45
General requirements for automotive design

EX1. Gearbox Design

46
 Vehicle Load and Calculation
Modes

1. Determination and
classification of load modes
2. Load modes
• Durability by Forces and
moments (Bending, Torsing)
• Contact Durability (contact
stress)
• Firmness
• Longevity
• Stability
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Vehicle Load and Calculation Modes

1. Determination and classification of load modes

Load = Forces or/and moments on parts, systems,…

48
Vehicle Load and Calculation Modes

1. Determination and classification of load modes

Statistic loads: constant by time – gravity load

Dynamic loads : variable by time – inertial load

Pulse loads: big value on short time – crankshaft load

Cycle loads: repeat by time – engine load

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Vehicle Load and Calculation Modes

2. Calculation modes
Durability:
- Maximum load → stress calculation → 𝝈𝒎𝒂𝒙 →
𝝈
- If 𝒎𝒂𝒙 < [𝝈] → OK, else redesign
where [𝝈] is an allowable limit stress for this material
𝝈𝒈
- Safety coefficient 𝒏=
[𝝈]
where, 𝝈𝒈 - Static allowable tress
- n=1.1-1.3 – for parts, details, which have low effects on others.
- n=1.3-3 – for parts, details, when its are wrong, damaged do not
cause serious consequences.
- n=3-5 – for main parts, details
50
Vehicle Load and Calculation Modes

2. Calculation modes

51
Vehicle Load and Calculation Modes

2. Calculation modes
Contact Durability / Surface Durability

Stickiness is the main parameter of surface durability calculation

52
Vehicle Load and Calculation Modes

2. Calculation modes
Firmness – gearbox shafts

53
Vehicle Load and Calculation Modes

2. Calculation modes
Firmness – gearbox shafts

54
Vehicle Load and Calculation Modes

2. Calculation modes
Longevity

tensile
Cycles

Stress
press

55
Vehicle Load and Calculation Modes

2. Calculation modes
Longevity

56
 Vehicle Load and Calculation Modes

2. Calculation modes
Longevity

- If 𝜎 < 𝜎𝑒
→ no damage by time
- If 𝜎 = 𝜎𝑖 < 𝜎𝑒
→ damage after Ni
cycles of working

Notes:
1. Stress is variable by time, and maybe a random value
2. Life curve was developed at laboratory only with constant conditions and loads

Longevity calculation is very difficult

57
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

2. Layout plans

• ICE – engine, Gearbox

• Active axles

• Vehicle with many active axles

3. Load distribution on the axles

58
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

59
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

Combustion Engine

60
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

Combustion Engine

61
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

Electric vehicle

62
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

Hybrid vehicle

63
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

Active axles
Requirements: max traction force

Gphi – Load on the axle, phi - adhesion coefficient

Choose: Active axle – Axle with the max load

Choose: How many Active axles?

64
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

1. The view of the layout of the basic parts

Weight distribution on car axles

Vehicle type Weight

Net weight Full-load weight
Car with front active axle 61/39 49/51
Car with rear active axle 53/47 43/57
Car with rear engine 40/60 41/59
Truck 48/52 28/72
Truck-Trailer 52/48 28/72
Trailer 53/47 50/50
Bus 36/67 37/63

65
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan
Combustion Engine layout

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VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan
Combustion Engine layout

67
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan Active axles

68
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan
Driveline layout

Front engine + Rear active axle

1- engine, 2- clutch, 3- gearbox, 4- cardan shaft, 5- final

drive and differential, 6- final shaft

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VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan
Driveline layout

Front engine + Front active axle

1- engine, 2- clutch, 3- gearbox, 4- cardan shaft, 5- final

drive and differential, 6- final shaft

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VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan
Driveline layout for bus

1- engine, 2- clutch, 3- gearbox, 4- cardan shaft, 5- final

drive and differential, 6- final shaft
71
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan
Driveline layout for multi-active axles

1- engine, 2- clutch, 3- gearbox, 4- cardan shaft, 5- final

drive and differential, 6- final shaft, 7- distribution box
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VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan

Design Problems of vehicle with multi-active axles – power Recycle

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VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

3. Load distribution on the axles

Vehicle with 2 axles

Load on front axle : G1=Z1

Load on front axle : G2=Z2

Vehicle with more 2 axles

Load on front axle : G1=Z1

Load on front axle : G2=Z21+Z22+Z23….

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VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

3. Load distribution on the axles

Weight distribution on car axles

Vehicle type Weight

Net weight Full-load weight
Car with front active axle 61/39 49/51
Car with rear active axle 53/47 43/57
Car with rear engine 40/60 41/59
Truck 48/52 28/72
Truck-Trailer 52/48 28/72
Trailer 53/47 50/50
Bus 36/67 37/63

75
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

3. Load distribution on the axles

QCVN 09 : 2011/BGTVT
QUY CHUẨN KỸ THUẬT QUỐC GIA VỀ CHẤT LƯỢNG AN TOÀN KỸ THUẬT
VÀ BẢO VỆ MÔI TRƯỜNG ĐỐI VỚI Ô TÔ

Limited Load on axle

76
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

3. Load distribution on the axles

QCVN 09 : 2011/BGTVT
QUY CHUẨN KỸ THUẬT QUỐC GIA VỀ CHẤT LƯỢNG AN TOÀN KỸ THUẬT
VÀ BẢO VỆ MÔI TRƯỜNG ĐỐI VỚI Ô TÔ
Exercise

1. Full vehicle Load : G=18t

Load on front axle: G1=G/3
Load on rear axles (2/3): G2=2G/3
2. Full vehicle Load : G=30t
Load on front axle 30%: G1=0.3*G
Load on rear axles 70%: G2=0.7*G

1. Number of rear axles?

2. Load on axles?
3. Number of active axles?
4. Schema of powertrain layout

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THANK YOU !

78