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

2
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

6
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

7
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

18
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.

19
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

20
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

22
 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

23
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

24
 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

25
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

26
General requirements for automotive design

1.4 Automobiles Design and Manufacturing

Design

Make
Correction samples
3-5 years

Experiments
and testing Assembly

27
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
47
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

49
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

66
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

69
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

70
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
72
VEHICLE GENERAL PLACEMENT OF MAIN SYSTEMS

2. Layout plan

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

73
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….

74
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

77
THANK YOU !

78
MODERN AUTOMOTIVE DESIGN

Le Van Nghia, PhD

Faculty of Transportation Engineering
Chapter 2: Body design

• • Review the role of the stylist and aerodynamics

• • Give an overview of the design stages from
concept to final design
• • Demonstrate the need for engineers and stylist to
work in tandem.

3
Chapter 3: Body design Aerodynamics

• • Review the role of the stylist and aerodynamics.

• • Review the basic aerodynamic concepts related to
vehicles.
• • Indicate the basic computations required
aerodynamic design.

4
Chapter 3: Body design Aerodynamics

• 5.1 Introduction
• 5.2 Aerodynamic forces

5
Chapter 3: Body design Aerodynamics
• 5.3 Drag

6
Chapter 3: Body design Aerodynamics
• 5.4 Drag reduction

7
Chapter 3: Body design Aerodynamics

8
Chapter 3: Body design Aerodynamics

9
Chapter 3: Body design Aerodynamics

10
Chapter 3: Body design Aerodynamics
• 5.5 Stability and cross-winds

11
Chapter 3: Body design Aerodynamics
• 5.6 Noise

12
Chapter 3: Body design Aerodynamics
• 5.7 Underhood ventilation
• The evidence from numerous researchers suggests that the engine cooling system is
responsible for between 10% and 15% of the overall vehicle drag, so it is not surprising to
note that considerable effort has been focused upon the optimization of these flows.
Traditionally the cooling drag has been determined from wind tunnel drag measurements
with and without the cooling intakes blanked-off. The results from those wind tunnel tests
must be treated with caution since the closure of the intakes may alter the entire flow-field
around a car.

13
Chapter 3: Body design Aerodynamics
• 5.8 Cabin ventilation
• Sealing between the body panels and particularly around the doors has achieved benefits
in terms of noise reduction and aerodynamic drag, but the almost complete elimination of
leakage flows has also led to changes in the design of passenger compartment ventilation.
To achieve the required ventilation flow rates greater attention must be paid not only to
the intake and exit locations but also to the velocity and path of the fresh air through the
passenger compartment.
• The intake should be located in a zone of relatively high pressure and it should not be too
close to the road surface where particulate and pollutant levels tend to be highest.

14
Chapter 3: Body design Aerodynamics

VEHICLE BODY DESIGN PROCESS

• 1. General layout and overall design of the car;
• 2. Preliminary design of the car body;
• 3. 3D design on computer;
• 4. Build 1:4 scale model;
• 5. Simulation in space (on computer);
• 6. Build 1:1 scale model;
• 7. Color and material selection.

15
Chapter 3: Body design Aerodynamics

1. General layout and overall design

16
Chapter 3: Body design Aerodynamics

2. Preliminary design + 3D design

17
Chapter 3: Body design Aerodynamics

3. Build 1:4 scale model

18
Chapter 3: Body design Aerodynamics
5. Simulation in space (on computer)

19
Chapter 3: Body design Aerodynamics
5. Simulation in space (on computer)

20
Chapter 3: Body design Aerodynamics

5. Simulation in space (on computer)

21
Chapter 3: Body design Aerodynamics
6. Build 1:1 scale model;

22
Chapter 3: Body design Aerodynamics
7. Color and material selection;

23
Chapter 3: Body design Aerodynamics

24
Chapter 3: Body design Aerodynamics

25
Chapter 3: Body design Aerodynamics

26
Chapter 3: Body design Aerodynamics

27
THANK YOU !

28
MODERN AUTOMOTIVE DESIGN

Le Van Nghia, PhD

Faculty of Transportation Engineering
Chapter 3: Engine and energy source choosing

• • Requirements about Engine and

energy source

• • Types of Engine and energy source

• • Calculation of engine power and

energy storage

3
 Chapter 3: Engine and energy source choosing

• • Requirements about Engine and energy

source
- Power for vehicle functioning

- Emission from vehicle engine

- Noise from vehicle and engine

- Vehicle utilization

4
 Chapter 3: Engine and energy source choosing

• • Requirements about Engine and

energy source
Power for vehicle functioning
1. Power for motion on [Link]

2. Power for accessory systems

3. Power for working machines

5
 Chapter 3: Engine and energy source choosing
• • Requirements about Engine and energy
source
- Emission from vehicle engine
Emission standards are the legal requirements governing air pollutants
released into the atmosphere. Emission standards set quantitative limits on
the permissible amount of specific air pollutants that may be released from
specific sources over specific timeframes.

CO = Carbon Monoxide
NOx = Oxides of Nitrogen
HC = Hydrocarbons
PM = Particulate matter

6
 Chapter 3: Engine and energy source choosing

• • Requirements about Engine and energy

source
- Noise from vehicle and engine

ISO standards: ISO 10844:2014, ISO/PAS 11819-

4:2013, ISO 13472-2:2010

UN/ECE regulations: UN/ECE R9, R41, R51, R63, R117

Vietnam standards: QCVN 24/2016/BYT, TCVN 7880 :

2008
7
 Chapter 3: Engine and energy source choosing

• • Requirements about Engine and energy

source
- Vehicle utilizations

Vehicle utilization is a measure of demand compared

to some type of capacity or threshold. The value is
often expressed as a percentage. For example, if 5 out
of 10 vehicles in a fleet are used in a given period of
time, we might say our utilization rate is 5/10 or 50% for
that period of time.

8
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Internal combustion engine Electric Engine

9
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Internal combustion engine:

-Petrol engine

-Diesel engine

-Gas engine

Differences?

10
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

External characteristic of ICE

11
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Operating characteristics of ICE

12
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Electric engine:

-DC motor

-3-phase motor

13
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

External characteristic of electric motor

14
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Energy source
1. Fossil fuel

-Petrol: Ron 92,Ron 92E5, Ron95,

Ron95E5, Ron98,…

-Diesel: DO 0,005%S (%S< 500mg/kg)

and DO 0,25%S (%S< 500mg/kg)

-Gas, CNG: types? using area?

15
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Energy source
Fossil fuel efficiency

16
Chapter 3: Engine and energy source choosing

• • Types of Engine and energy source

Energy source
2. Electric source

o Electrical grid: Thermal power plan,

Hydropower plan, Nuclear power plan,
Renewable electrical plans – solar
energy, wind energy, …

o Batteries: Lithium-Ion (Li-On),

Nickel-Metal Hybrid (NiMH), Lead
Acid (SLA), Ultracapacitor, ZEBRA
(Zero Emissions Batteries Research
Activity).

o Fuel cell: Hydro-technology

17
Chapter 3: Engine and energy source choosing
• • Types of Engine and energy source
Energy source
Energy efficiency of EV

18
Chapter 3: Engine and energy source choosing
• • Types of Engine and energy source
Energy source

19
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and

energy storage
Power for vehicle functioning
1. Road Power for vehicle motion
𝑃𝑟𝑜𝑎𝑑 = 𝑃𝑎𝑒𝑟𝑜 + 𝑃𝑟𝑜𝑙𝑙 + 𝑃𝑎𝑐𝑒𝑙𝑙 + 𝑃𝑔𝑟𝑎𝑑𝑒
❑𝑃𝑟𝑜𝑎𝑑 is the road load power (W),
❑𝑃𝑎𝑒𝑟𝑜 is the air resistance power (W),
❑𝑃𝑟𝑜𝑙𝑙 is the rolling resistance power (W),
❑𝑃𝑎𝑐𝑒𝑙𝑙 is the inertial power (W),
❑𝑃𝑔𝑟𝑎𝑑𝑒 is the grade resistance power (W),

20
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and energy

storage
Power for vehicle functioning
1. Road Power for vehicle motion
𝑃𝑟𝑜𝑎𝑑 = 𝑃𝑎𝑒𝑟𝑜 + 𝑃𝑟𝑜𝑙𝑙 + 𝑃𝑎𝑐𝑒𝑙𝑙 + 𝑃𝑔𝑟𝑎𝑑𝑒
1
=  CD Av3 + CRR mtotal gv + km mtotal av + mtotal gZv
2
v is the vehicle speed (m/s), ρ is the density of air, a is the vehicle acceleration (m/s2),
𝐶𝐷 is the aerodynamic drag coefficient, A is the frontal area (m2), 𝐶𝑅𝑅 is the rolling
resistance coefficient, 𝑚𝑡𝑜𝑡𝑎𝑙 is the total vehicle mass (kg), g is the gravitational
acceleration (9.81 m/s2 ), Z is the road gradient (%) and 𝑘𝑚 represents the rotational
inertia of the powertrain.

21
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and energy

storage
Power for vehicle functioning
1. Needed Power for motion on [Link]

𝑃𝑟𝑜𝑎𝑑 = 𝑃𝑎𝑒𝑟𝑜 + 𝑃𝑟𝑜𝑙𝑙 + 𝑃𝑔𝑟𝑎𝑑𝑒

1
=  CD Av3 + CRR mtotal gv + mtotal gZv
2
V max = 200km / h, mtotal = 1500kg , g = 9.81m / s 2
𝑃𝑟𝑜𝑎𝑑 =?  = 1.21, CD = 0.3, A = 2*1.5m2,
CRR = 0.01, Z = 0.05
22
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and energy

storage
Power for vehicle functioning
1. Needed Power for motion on [Link]

𝑃𝑟𝑜𝑎𝑑 = 𝑃𝑎𝑒𝑟𝑜 + 𝑃𝑟𝑜𝑙𝑙 + 𝑃𝑔𝑟𝑎𝑑𝑒

1
=  CD Av3 + CRR mtotal gv + mtotal gZv
2
V max = 200km / h, mtotal = 1500kg , g = 9.81m / s 2
𝑃𝑟𝑜𝑎𝑑 =?  = 1.21, CD = 0.3, A = 2*1.5m2,
CRR = 0.01, Z = 0.05
23
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and energy

storage
Power for vehicle functioning
1. Needed Power for Engine at [Link]
𝑃𝑟𝑜𝑎𝑑
𝑃𝑒𝑛𝑔 = + 𝑃𝑎𝑐𝑒𝑠𝑠𝑜𝑟𝑦
𝜂𝑡𝑟𝑎𝑛𝑠
𝜂𝑡𝑟𝑎𝑛𝑠 = 𝜂𝑐𝑙𝑢𝑡𝑐ℎ ∗ 𝜂𝑔𝑒𝑎𝑟𝑏𝑜𝑥 ∗ 𝜂𝑓𝑖𝑛𝑎𝑙𝑑𝑟𝑖𝑣𝑒𝑟 ≈ 0.85� -
efficiency of transmission
𝑃𝑎𝑐𝑒𝑠𝑠𝑜𝑟𝑦 =15-25% of 𝑃𝑟𝑜𝑎𝑑

24
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and energy

storage
For Electric vehicle, need to check vehicle dynamic after
motor choosing

1. Check vehicle motion on acceleration

2. Check vehicle motion on grade at [Link]

25
 Chapter 3: Engine and energy source choosing

• • Calculation of engine power and energy

storage
Trend of engine choosing by regions?

1. America: more power, more comfort

2. Euro: power and fuel consumption

3. Asia: fuel consumption, low power

26
THANK YOU !

27
MODERN AUTOMOTIVE DESIGN

Le Van Nghia, PhD

Faculty of Transportation Engineering
Chapter 4: Transmissions and driveline

• Introduction
• Demonstrate the need for transmission design and
matching.

• Give examples of common clutch, gearboxes and

transmissions available for vehicle design.

• Indicate the terminology and methods for transmission

design.

• Aid the designer to understand the elements of the

analysis of transmission systems.

3
Chapter 4: Transmissions and driveline

What the vehicle requires from the transmission

✓ Allowing the vehicle to start from rest, with the engine running continuously.

✓ Letting the vehicle stop by disconnecting the drive when appropriate.

✓ Enabling the vehicle to start at varied rates, under a controlled manner.

✓ Varying the speed ratio between the engine and wheels.

✓ Allowing this ratio to change when required.

✓ Transmitting the drive torque to the required wheels.

4
Chapter 4: Transmissions and driveline

Transmission’s components

5
Chapter 4: Transmissions and driveline

Clutch
1. Clutch overview

2. Structure of clutches

3. Clutch design
- Determination of needed torque
- Design of clutch mechanism
- Design of clutch driver

6
Chapter 4: Transmissions and driveline

Clutch
1. Clutch overview
- Clutch position: between engine and gearbox

- Clutch functions:
1. The clutch helps the engine to run at a stationary position.
2. It can be used to reduce engine speed.
3. It enables easy changing of gears.
4. Smooth vehicle control is achieved.
5. It’s a safety element for transmission.

7
Chapter 4: Transmissions and driveline

Clutch
1. Clutch overview
- Clutch position

- Clutch functions

- Clutch classifications:
• Manual clutches (dry friction clutch).
• Hydraulic clutches (hydraulic torque converter).
• Electric clutches (air compressor, differential).
• Centrifugal clutches (motorbike).

8
Chapter 4: Transmissions and driveline

Clutch
1. Clutch overview
- Clutch position
- Clutch functions
- Clutch classifications:
• Dry clutch classification
• Single-Plate Clutch – Advantages and Disadvantages?

• Double-Plate Clutch – Advantages and Disadvantages?

• Dry clutch with diagram spring, coil spring, conical spring

• Automatic or semi-automatic Dry clutch, manual clutch

9
Chapter 4: Transmissions and driveline
Clutch
1. Clutch overview
Clutch disks

Advantages and Disadvantages ?

10
Chapter 4: Transmissions and driveline
Clutch
1. Clutch overview
Clutch springs

Solo Adjustment-Free Heavy Duty Clutch

11
Chapter 4: Transmissions and driveline
Clutch
1. Clutch overview
Automated clutches

pneumatic actuator

Electric actuator

12
Chapter 4: Transmissions and driveline
Clutch
1. Clutch overview
clutch-by-wire with electronic hydraulic actuator

13
 Chapter 4: Transmissions and driveline

Clutch
2. Structure of clutch system

Working scheme of Clutch system

1-Flywheel; 2-Friction disk; 3-Pressure plate; 4-Pressure spring; 5-Clutch cover; 6-Realease
bushing; 7-Clutch pedal; 8-return spring; 9-pull lever; 10-open lever; 11-Realease bearing;12-
open bar; 13-damper; 14-Intermediate plate; 15-return spring.

14
Chapter 4: Transmissions and driveline

Clutch
2. Structure of clutch system

Clutch structure
1-Flywheel; 2-Friction disk; 3-Pressure plate;
4-Pressure spring; 5-Clutch cover; 6-Realease
bushing; 7-Clutch pedal; 8-return spring; 9-
pull lever; 10-open lever; 11-Realease
bearing;12-open bar; 13-damper; 14-
Intermediate plate; 15-return spring.

15
Chapter 4: Transmissions and driveline

Clutch
2. Structure of clutch system

Clutch manipulating mechanism

[Link] mass flywheel, [Link] cover, [Link] releaser, [Link] vibration damping device, [Link]
master cylinder (CMC), [Link] clutch pedal, [Link] slave cylinder (CSC), [Link] (friction) disc

16
Chapter 4: Transmissions and driveline

Clutch
2. Structure of clutch system
Pressure spring

a) Diaphragm spring b) coil spring c) conical spring

17
Chapter 4: Transmissions and driveline

Clutch
2. Structure of clutch system
Pressure spring characteristics

Diaphragm spring coil spring conical spring

18
Chapter 4: Transmissions and driveline

Clutch
2. Structure of clutch system
Clutch friction disc

19
 Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
- General requirements of clutch
• –Transmit Full Engine Torque without slipping;
• –Definitively disengage and softly engage for reduction dynamic load on
transmission;
• –The inertia moment of the passive part should be as small as possible in
order to reduce the dynamic load on the gears and the synchronizer during
gear shifting;
• –Frictional torque remains constant when clutch is engaged;
• –Avoid resonance in transmission with high frequency of combustion
engine;
• –Good heat dissipation to avoid heating the parts while clutch slipping;
• –Long life, compact size, easy to use, maintain and repair, low cost.

20
 Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
- General requirements of clutch design
• ✓ Ensure good performance of functions and tasks;
• ✓ Minimum size and volume;
• ✓ Durable, long life, low cost;
• ✓ High reliability, convenient in use, maintenance and repair, low cost;
✓Defining basic parameters
→ Setting up the sketch
drawing;
✓Check working conditions,
operability;
✓Calculation of details
(dimensions, materials,
Base clutch technical requirements,
Designed clutch durability assessment, ...);
21
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
- 3.1 Clutch Necessary Friction Torque

Memax – engine max. torque

ᵦ- reserve coefficient - Passenger car, commercial car

-Truck, bus
- Vehicle with high maneuverability
- Semi-truck, trailer
Designed clutch
22
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
- 3.2 Clutch mechanism design

✓ Number of friction discs;

✓ The dimensions of the friction disc;

✓ Required pressure force;

✓ Number of springs, force of a spring;

✓ Dampers (springs, friction plates).

23
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Friction Torque

Mc – friction torque
η – friction coefficient 0.25-0.35
FN – pressure force
Rη – friction radius
zη – number of friction disc

24
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Friction disc diameters

– small passenger car

– truck, bus
– vehicle with hard working condition

– if ne – fast engine (petrol engine), choose r smaller

– if ne – low engine (diesel engine), choose r bigger

25
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Friction pressure force

check pressure on the friction surfaces:

26
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Slipping energy Specify Slipping energy

Engage process Engage process modelling

Calculation of Engage process
27
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Slipping energy calculation

t1
Assumption 𝑀𝑐 (𝑡) = 𝑘 ∗ 𝑡, 𝑀𝑑 (𝑡) = 𝑘 ∗ 𝑡
𝑀𝑑 = 𝑀𝜓 = 𝑘 ∗ 𝑡1

28
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Slipping energy calculation

Assumption:
𝜂𝑡𝑟𝑎𝑛𝑠
𝑀𝑑 = 𝑀𝜓 = 𝜓 ∗ 𝐺 ∗ 𝑟𝑤ℎ ∗ = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑖𝑡𝑟𝑎𝑛𝑠
𝑀𝑐 = 𝑀𝜓 + 𝑘 ∗ 𝑡

t1 𝜔𝑑 =?
𝑡2 𝜔𝑎 =?
𝑊2 = න (𝑀𝜓 + 𝑘 ∗ 𝑡) ∗ (𝜔𝑑 − 𝜔𝑎 ) 𝑡2 =?
0

29
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Slipping energy calculation
𝐼𝑑 ∗ 𝜔𝑑ሶ = 𝑀𝑑 − 𝑀𝑐 = −𝑘 ∗ 𝑡 𝜔𝑑 = 𝜔0 − 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼𝑑

𝐼𝑎 ∗ 𝜔𝑎ሶ = 𝑀𝑐 − 𝑀𝜓 = 𝑘 ∗ 𝑡 𝜔𝑎 = 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼𝑎

𝜔𝑑 − 𝜔𝑎 = 𝜔0 − 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼
𝐴𝑡 𝑡ℎ𝑒 𝑡2 𝑚𝑜𝑚𝑒𝑛𝑡: 𝜔𝑑 = 𝜔𝑎 𝑎𝑛𝑑 𝑡2 = 2 ∗ 𝜔0 ∗ 𝐼/𝑘

30
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Slipping energy calculation

31
Chapter 4: Transmissions and driveline

Clutch
3. Clutch design
Slipping energy calculation
- Petrol engine

- Diesel engine

ωM, ωN – engine speed at max. torque and max. power

Vehicle type Ψ Gear number Limited of Specify
Slipping energy J/cm2
MΨ=? Passenger Car 0.1 II 160
Truck 0.1 II 160

32
Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Slipping energy calculation

Vehicle type Ψ Gear number Limited of Specify Slipping

energy J/cm2
Truck 0.02 I 20
0.16 I 45
0.02 II 40
Passenger Car 0.1 II 50---70

33
Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Thermal calculation on engage process

c = 481,5 J/kg.○C - specific heat capacity of steel

md – mass of pressure plate, [kg]
For single vehicle
For trailer

34
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Pressure spring calculation – coil spring
Pressure Force:

Force for disengage:

Choose the number of pressure spring Zlx: Characteristic of coil spring

mm- Singer plate
mm- Double plate

Spring stiffness:

35
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Pressure spring calculation – coil spring
Cut stress:

36
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Diaphragm Spring calculation

FN – force at pressure plate

Fn – disengage force

37
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Diaphragm Spring calculation

38
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Diaphragm Spring calculation

Recommendation:

Number of diaphragm spring blades: 8-20

h/δ >1.6 – big range of constant force
h/δ >2.8 – maybe spring reversing

39
 Chapter 4: Transmissions and driveline
Clutch Cushion segment
3. Clutch design
Damp spring
Damp Spring calculation
Damp Torque :
Friction plate

Center hub
Torque of damp spring: (splined)
Gearbox Input
shaft
Torque of friction disc:
Splined

40
 Chapter 4: Transmissions and driveline
Clutch Cushion segment
3. Clutch design
Damp spring
Damp Spring calculation
Recommendations:
Friction plate

Center hub
(splined)
Gearbox Input
shaft
M’lx – initial damp spring torque
φg – max. angle between cushion and splined Splined

Damp spring: D/d=4.5-5.5, where D – spring diameter, d- diameter of coil

Diameter of spring assembled place : 80-120 mm,
Length of spring assembled place: 25-27mm

41
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Damp Spring calculation D=

Recommendations:

Damp spring: D/d=4.5-5.5, where D – spring diameter, d- diameter of coil

Diameter of spring assembled place : 80-120 mm,
Length of spring assembled place: 25-27mm
Damp spring parameters:
d= 3-4 mm, D=14-19 mm
Turns Number: i=3-4
Distance between turns: Δ=3-4 mm

42
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Release fork calculation:

Zdm – fork number

Wu – blend moment at calculated section
Steel fork -

Cast iron -
43
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Friction disc calculation:
Calculation of Rivets, which connect
friction pad to cushion segment
Forces on rivets:

Cut and bearing (stamping) stresses

Materials: Al or Cu
d – rivet diameter= 4-6mm
n1 and n2 – rivets numbers

44
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Friction disc calculation:

Calculation of Rivets, which connect

friction disc to spined hub

Calculation Method is the same, but the limited

values of stresses are:

Materials: Steel- Fe
d – rivet diameter= 6-10mm

45
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Splined hub calculation:

Standard?
Material?
Dimensions?
Length L=(1-1.4)*d

46
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch shaft calculation:

Clutch shaft = Gearbox

input shaft
Shaft material = material for gear

47
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design

48
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Exercise: Design a clutch mechanism for 7-seats car based on Toyota Inova 2019
Main steps of Design process:
Step1: Analysis the nowadays construction of clutch mechanism of popular 7-seats
on the market → conclusion about the main type of and choose the type of clutch
mechanism (dry clutch, west clutch, hydraulic clutch,…)
Step2: Analysis the type and construction of the main parts of clutch → conclusion
about the main part type of clutch mechanism (pressure spring, pressure plate,
friction plates, release bearing,…) → select the right types
Step3: Calculate the main parameters of main elements → check out the element’s
durability and draw the clutch mechanism sketch
Step4: Study on clutch mechanism functions by simulation on computer →
optimization the values of main parameters
Step5: Build the assembled drawing → and details drawings
Step6: Make a proper type of designed clutch mechanism → Test on stand
Step7: Test on vehicle → conclusion about production

49
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Mission: Help driver control clutch mechanism
Type: Mechanical, Hydraulic, Hydraulic with vacuum power assistant,
Hydropneumatics, Mechanical with pneumatic power assistant.

Mechanical driver

Hydraulic with vacuum

Hydraulic driver
power assistant

Hydropneumatics
Press_air
50
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Main parameters of clutch driver
- Pedal force Qbd;
- Pedal travel Sbd; Sbd=So+Slv
- Clutch driver ratio.

Standard values:
- Qbd <[Q]
- Sbd < [S]
- Small car: [Q]=150N, and [S]=140-160 mm
- Truck, bus: [Q]=250N without power assistant, [Q]=150N with power assistant
and [S]=180 mm

51
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Mechanical clutch driver
• Δ = 1,5 - 2,0 mm – Single disc
• Δ = 2,0 - 3,0 mm – Double disc
• δ = 2,0 - 4,0 mm
There are two ways to design clutch driver
- M1: Choose Qbd <[Q]

Choose dimensions a,b,c by real structure

Free pedal travel
Working pedal travel
Check the pedal travel

52
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Mechanical clutch driver
• Δ = 1,5 - 2,0 mm – Single disc
• Δ = 2,0 - 3,0 mm – Double disc
• δ = 2,0 - 4,0 mm
There are two ways to design clutch driver
- M2: Choose free pedal travel So
Small car
Truck, bus

If Qbd>[Q]?

53
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Hydraulic clutch driver – same as mechanical one
• Δ = 1,5 - 2,0 mm – Single disc
• Δ = 2,0 - 3,0 mm – Double disc
• δ = 2,0 - 4,0 mm

54
 Chapter 4: Transmissions and driveline
Clutch
pk = (0,7 – 0,8) MPa
3. Clutch design
Clutch driver calculation:
Hydraulic clutch driver
with pneumatic power assistant
- Choose Sbd and So
- Calculate

- Choose a,b,c and calculate

-

Pressure air

- Divide the pedal force:

- Choose the drive force: --- assistant force:

- Force from cylinder:

55
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design - Sbd?
- Qbd without power assistant?
Clutch driver calculation: - Area of vacuum cylinder if Δh=0,05MPa?
Hydraulic clutch driver with vacuum power assistant
-

air Vacuum

56
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Notes for diaphragm spring

57
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Clutch driver calculation:
Notes for diaphragm spring

58
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design

59
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design

60
 Chapter 4: Transmissions and driveline
Clutch
3. Clutch design
Exercise: Design a clutch driver for 7-seats car based on Toyota Inova 2019
Main steps of Design process:
Step1: Analysis the nowadays construction of clutch driver of popular 7-seats on the
market → conclusion about the main type of and choose the type of clutch driver
(mechanical, hydraulic, hydraulic with power assistant,…)
Step2: Analysis the type and construction of the main parts of clutch driver →
conclusion about the main part type of clutch driver (power cylinder, pressure, pipe,
vacuum chamber,…) → select the right types
Step3: Calculate the main parameters of main elements → check out the element’s
durability and draw the clutch driver sketch
Step4: Study on clutch driver functions by simulation on computer → optimization
the values of main parameters
Step5: Build the assembled drawing → and details drawings
Step6: Make a proper type of designed clutch driver → Test on stand
Step7: Test on vehicle → conclusion about mass production

61
Chapter 4: Transmissions and driveline

Stepped Gearbox
1. Gearbox overview

2. Structure of gearbox

3. Gearbox design
- Determination of gear ratios
- Design of gearbox’s components
- Design of gearbox’s shifting mechanism

62
 Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview
- Gearbox position: after clutch and before final driver

Active wheel

Final driver
Engine Gearbox

Main final driver

Clutch Auxiliary gearbox Auxiliary gearbox Main final driver

63
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview
- Gearbox functions:
1. Changing the gear ratios.
2. Break the power from engine to transmission.
3. Reverse motion of vehicle.

- Gearbox Classification:
1. By structure: 2-shafts or 3-shafts gearbox
2. By position between input and output shafts: coaxial and no-coaxial gearbox
3. By control method: manual, semi-manual, automatic

64
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview
- Gearbox Classification:
1. By structure: 2-shafts or 3-shafts gearbox

65
 Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview
- Automatic gearbox:
• AT: Automatic Transmissions;
• CVT: Continuously Variable Transmissions;
• DCT: Dual Clutch Transmissions;
• AMT: Automated Manual Transmissions

66
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview
- General Gearbox’s requirements:
1. Have the appropriate number of gears and gear ratios to ensure the vehicle's dynamics
and fuel economy.
2. Soft shifting gear without noise .
3. Have an anti-shifting mechanism and an anti-setting mechanism for two gears at the
same time.
4. Have a cutting power position from engine
5. Have a signaling mechanism when reverse gear is engaged
6. Have a point for sharing power if needed

67
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview

2-shaft Gearbox

68
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview

3-shaft Gearbox

69
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview – comparison between 2 and 3-shaft gearbox

- Translate power by 2 couple gear

+ Translate power by 1 couple gear →Low efficiency
→Hight efficiency + First gear ratio can be big as needed
+ First gear ratio is not big + Have a direct gear = 1 gear ratio
Hight efficiency ≈1
Direct Working Low Fuel consumption
gear time ≈
No load on elements 70-80 % Hight longevity

70
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview – Gear ratios

i1 i1
Tractive force

Tractive force
i2
i2
Ideal tractive force Ideal tractive force
i3

i3 i4
i4
i5 i5

speed speed
Progressive Geometric progress

71
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview – Gear ratios

72
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview – Gear ratios
1. Influence of gear ratio to fuel consumption
Driver →gas pedal → Vehicle speed: V
Vehicle power: P=V*Fc
Road → resistant → Fc
2. Wheel speed

3. Engine speed

For speed V → choose iT → ne with minimum ge

73
Chapter 4: Transmissions and driveline

Gearbox
1. Gearbox overview – Gear ratios

74
Chapter 4: Transmissions and driveline

Gearbox
2. Structure of Gearbox
- Gearbox main components: Gear couples, synchronizers,
shafts, bearings, shifting mechanism, lubrication system,

75
Chapter 4: Transmissions and driveline

Gearbox
3. Gearbox design
✓Gear couple
- Main geometrical parameters
- Stress dupability

✓Shaft
- Diameters of main parts
- Stress dupability
- Firmness

✓Bearing : choose the needed bearing and check

✓Lubrication

76
Chapter 4: Transmissions and driveline

Cardan Shaft
➢Cardan Shaft overview

➢Structure of Cardan Shaft

➢Cardan Shaft design

➢Design of cross match
➢Shaft Design

77
Chapter 4: Transmissions and driveline

Cardan Shaft
➢Cardan Shaft overview
➢ Function: connect 2 rotation shafts
1. Gearbox
2. Cross match
3. Active axle
4. Hub
5. Middle bearing
6. Active shaft with
outside working
device
7. Distribution gearbox
8. Final drive
9. Synchronous joint
10. Active wheel

78
Chapter 4: Transmissions and driveline

Cardan Shaft
➢Cardan Shaft overview
➢ Classification: by 2 marks
- By the kinematic of shafts: Synchronous and unsynchronous
- By joint: cross match joint, expansion joint, hard coupling,..
➢ Requirements
- Synchronous shafts speed
- Hight efficiency
- Noise and hardness
- Longevity

79
Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Structure

1. Spigot 7. Yoke flange

2. Bearing cover 8. Felt washer
3. Needle rollers 9. Sliding end lubricator
4. Sliding end 10. Star piece
5. Dust cover 11. Relief valve
6. Lock strap 12. Gasket and retainer
80
Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Structure

Cardan
Joints

81
Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Structure
Cardan Joints:
Bendix-Weiss

82
Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Structure
Cardan Joints:
Rzeppa

83
Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Structure
Cardan shaft kinematic

84
 Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Design
Cardan shaft cross match

Load:

Cross section Cross section

Bending stress Bending stress

Cutting stress Cutting stress

85
 Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Design
Cardan shaft max speed

Centrifugal force:
E: Young’s modulus,
Elastic force: L: shaft length, m
m: shaft mass, kg
J: inertial moment, m4
C: coefficient

Force balance:

If shaft will be broken

Limited speed:

86
Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Design

Solid shaft Hollow shaft

Cardan shaft max speed

Normal structure

Design note:

87
 Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Design
Cardan shaft calculation

1. Max. torque: Mt=Memax* h; i

2. Determine diameters D and d by stress condition when loading Mt

or

88
 Chapter 4: Transmissions and driveline
Cardan Shaft
➢Cardan Shaft Design
Cardan shaft calculation

3. Calculate and check the limited speed of shaft

Vmax – max. speed of vehicle, it-b: ratio from cardan shaft to wheel
4. Calculate the max. length of cardan shaft

89
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver overview

➢Structure of Final driver

➢Final driver design

➢Design of Final driver
➢Shaft Design

90
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver overview
➢ Function: Make a ratio in order to increase the wheel torque
➢ Requirements
➢ Vehicle dynamic and fuel consumption with the chosen ratios
➢ Hight efficiency and low noise and vibration
➢ Make sure the ground clearance is large enough
➢ Make sure the firmness of structure (bearings and shafts
➢ Classification
➢ Single final driver
➢ Double final driver
➢ “wheel” driver

91
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver overview
➢ Classification
➢ Single final driver

92
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver overview
➢ Classification
➢ Double final driver

93
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver overview
➢ Classification
➢ “wheel” driver

94
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver overview
➢ Classification
➢ External “wheel” driver

95
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver design
➢ Caused by E, kinematic will be wrong→
Slipping→ Hight friction → lubrication

Tangential forces:

Comparison conical gear and hypoid gear

96
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver design
Forces in hypoid gear
➢ Hypoid gear design

r1 – radius of small end

b - length of gear

97
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver design
➢ Hypoid gear design
Forces on active gear
Tangential Forces

Axial Forces

Radial Forces
Forces on passive gear
Tangential Forces

Axial Forces

Radial Forces

98
Chapter 4: Transmissions and driveline

Final driver and differential

➢Final driver design
➢ Geometrical gear parameter

➢ E <0.2*de2 for passenger car

➢ E<0.125de2 for truck and bus Forces in hypoid gear

99
Chapter 4: Transmissions and driveline

Final driver and differential

➢Differential design
Kinematic:
Dynamic:
straight motion:
turn on:

1. Block differential
Poor escape ability Solution 2. Increase friction
3. Control differential
100
Chapter 4: Transmissions and driveline

Final driver and differential

➢Differential design
Differential Braking Coefficient Differential Locking Coefficient

Max. traction force

Chapter 4: Transmissions and driveline

Driver shaft design

➢Classification
a) Fully floating

b) Three-quarter floating

c) Semi-floating

X: Longitudinal force, Y: lateral force, Z: vertical force

Chapter 4: Transmissions and driveline

Driver shaft design

➢Fully floating shaft design
- Determine the main parameters of shaft by loading: d and L
- Check the durability by torsion stress and angle: τ and θ
Chapter 4: Transmissions and driveline

Driver shaft design

➢Semi-floating shaft design
Motion with

Motion with

Motion with Passenger car

Truck and bus
Special vehicle
Chapter 4: Transmissions and driveline

Active axle housing design

➢Rear active housing
Chapter 4: Transmissions and driveline

Active axle housing design

➢Rear active housing
1- Loading on axle:
- Vertical force: Zi
- Longitudinal force: Xi (traction and
braking)
- Lateral force: Yi
2- Calculation:
a) Moving with Xmax;
b) Moving with Ymax;
c) Moving with Zmax;
THANK YOU !

107
MODERN AUTOMOTIVE DESIGN

Le Van Nghia., PhD

Faculty of Transportation Engineering
Chapter 05: Braking systems

• Aid the designer to understand the legal

requirements of braking systems.
• Understand the basic requirements for braking
systems to be successful.
• Understand the design process for achieving an
efficient braking system.
• Appreciate the material requirements for efficient
braking systems.
• Understand current developments in braking control
systems.

3
Chapter 05: Braking systems

• Definitions
• Structures of braking system
➢Braking mechanism
➢Braking driver
• Braking system calculation
➢ Determination of needed braking torque
➢ Calculation of braking mechanism
➢ Calculation of braking driver

4
Chapter 05: Braking systems

• Definitions
• Function of braking system:
• Deacceleration
• Long Vehicle Stop on hill (20% -QCVN –09/2011)
• Classification
• By function: main brake, stop brake, auxiliary brake,
backup brake
• By structure of brake mechanism : drum brake, disc
brake
• By structure of brake driver: mechanical, hydraulic,
pneumatic, electric, combine

5
Chapter 05: Braking systems

• Definitions
• Requirements:
• Max. Deacceleration (legal requirement)
• Stability of braking progress (legal requirement)
• Highly sensitive of Brake drive (legal requirement)
• Low control force (legal requirement)
• Optimal Distribution of braking force
• No self-tightening phenomenon (drum brake)
• Good heat dissipation brake mechanism
• Hight friction coefficient on using process
• Linear relationship between control force and braking torque
• Long stop on hill (legal requirement)

6
Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – drum brake

7
Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – drum brake
• SIMPLEX

8
Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – drum brake
• DUPLEX and DUO-DUPLEX

9
Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – disc brake

Fixed caliper Moving caliper

10
Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – comparing
Drum mechanism Disc mechanism
- Hight weight - Low weight
- Hight stability of brake torque - Low stability of brake torque
- Small clearance between brake disc - Big clearance between brake disc and
and brake pad → low time of braking brake shoe→ Hight time of braking
action action
- brake pad – flat →uniformly - brake shoe – curved →infirmly
distributed pressure →uniformly wear distributed pressure →infirmly wear
- Open type → good heat dissipation - Closed type → poor heat dissipation
- Hight cost - Low cost

11
Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – comparing

T: Friction force
P: Driver force

Force transmission coefficient

of brake mechanism

12
Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – hydraulic type

Main components of system?

13
Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – pneumatic type
Main components of system?

14
Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – comparison
hydraulic type pneumatic type
- Low delay - Long delay
- Big control force caused by making - Small control force for opening or
working pressure closing valves
- Hight cost - Low cost

Pneuma-hydraulic type

- Small delay of system caused by reduction pneumatic line

- Control force on pneumatic valve

15
Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – pneuma-hydraulic type

Pneumatic lines
Hydrauic lines

16
 Chapter 05: Braking systems

• Braking system calculation

➢ Determination of needed braking torque
Max. braking force Max. braking torque:

Static vehicle
position

Vehicle braking
moment

17
Chapter 05: Braking systems

• Braking system calculation

➢ Determination of needed braking torque

Max. braking torque at axles

Max. braking torque on

front axle:

Max. braking torque on

rear axle:

18
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Main geometrical
parameters

Chooses: rt, a, b, h, beta

19
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Forces on drum brake: Drum
1. Drive forces: P’ and P’’
2. Reaction force from brake
latch U’ and U’’
3. Reaction force from drum R’
and R’’
Calculation Method:
1. Brake force graph
2. Using Approximate formulas

20
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 1 Total brake torque

For squeeze shoe For release shoe

K= 0.85-0.9 – regulator factor

Hydraulic

21
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 1

Hydraulic Self squeeze

22
Chapter 05: Braking systems

• Braking system calculation Self squeeze

➢ Drum brake mechanism design

Relationship between driver Forces and brake torque:
Method 2

Hydraulic

23
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 2
A and B coefficients will be depended on the rule of the surface force distribution
Uniform distribution Sinewave distribution

Note: all angles are measured in Rad

Self squeeze:
24
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 3 Brake force graph

25
 Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 3 Brake force graph

Rule of distribution:

Position of force R

26
 Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 3 Brake force graph

Direction of force R

Determine the cross section of all forces → direction of force U

Build the force triangle → determine the force value

27
Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Brake force graph
Method 3

28
Chapter 05: Braking systems

• Braking system calculation

➢ Disc brake mechanism design
• Brake torque:

• di – diameter of brake cylinder

• pt – working pressure

Choose the pt and calculate the di

29
Chapter 05: Braking systems

• Braking system calculation

➢ Disc brake mechanism design
• Brake pad calculation:
• Special Friction work:

• G= m*g – vehicle weight

• V – initial speed before braking, with V=60 km/h, [l]=400-1000 J/cm2
• AΣ – total brake pad area
• Surface pressure:

• For brake pad: [q]=5 Mpa with using new materials

• P ratio:
For passenger vehicle

For bus
For truck
30
Chapter 05: Braking systems

• Braking system calculation

➢ Disc brake mechanism design
• Brake pad calculation:
• Heat dissipation :

• G= m*g – vehicle weight

• V – initial speed before braking, with V=30 km/h, [t]=15 degree of celcius

• At – total heat dissipation area of drum or disc

• kt – coefficient of heat transmission

• C - specific heat , for steel c=500 J/[Link]

• T – braking time

31
Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver
Master cylinder

ib=a/b

Brake pedal Brake cylinder

32
Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver
Pi is calculated from needed brake torque, and
chosen pt

Choose Qb<[Q], and choose

a, b, nhuy_b

Number of piston Disc brake

Piston motion
Drum brake
compression
coefficient limit wear

33
Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver
Working pressure Recommendation on choosing
Brake without power assistant
Brake with power assistant
Brake with pump assistant
Cylinder diameters:
Drum brake

Disc brake

Master cylinder
34
Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver with vacuum booster
Vacuum booster
Master cylinder

ib=a/b
Brake pedal Brake cylinder
air vacuum

35
 Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver with vacuum booster
Without Without
Vacuum booster Vacuum
booster
With Vacuum booster

With VB
Ignore spring force and friction
With

Driver characteristic

36
Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Pneumatic driver design
➢ Pedal valve design
➢ Chamber design (by standard)
➢ Chamber with accumulative spring

37
Chapter 05: Braking systems

• Electronic control integrated on Braking system

➢ Anti-lock Braking System - ABS

➢ Braking force distribution -EBD

➢ Emergency brake assist - EBA

➢ Traction Control System - TCS

➢ Anti-Slip Regulation – ASR

➢ Electronic stability program - ESP

38
THANK YOU !

39