Vehicle Body Engineering: G.Vijay Bhaskar Asst - Prof Automobile Enginineering Dept

Vehicle Body Engineering
G.VIJAY BHASKAR
ASST.PROF
AUTOMOBILE ENGININEERING DEPT
Driving Intelligence
UNIT I
Active Vehicle Safety Systems Save Lives

We are on the frontier of a revolution in active vehicle safety
The technology to improve vehicle stability and reduce crashes is
here today
Surveys indicate safety systems, like electronic stability control, are
highly desired by consumers
Electronic stability control saves lives and money according to the
latest traffic studies
Continental is actively educating key stakeholders on critical active
safety technology
Our Industry is Under Siege
Crashes Cost Americans $230 Billion

6.3 million passenger vehicle crashes in 2002
Nearly 3 million injuries and 42,815 fatalities
253,000 passenger vehicle rollovers
Injuries declined, but fatalities increased
Highest number of fatalities since 1990
Rollovers accounted for 82% of the increase in fatalities
95% of all crashes due at least in part to driver error
$230.6 billion economic cost to society

The Motor Vehicle Safety

Equipment Exists Now to Help
Reduce Crashes and Rollovers
Its Called Electronic
Stability Control
Technology
is our passion but
safety
is our business
Electronic Stability Control Improves Safety
We Have Safety Technology Today to Make

Mobility Safer!
The Bottom Line
Make the chassis itself

electronically intelligent
Raise comfort and safety to new

levels without sacrifices
Passive Safety is Job Three
The next frontier is

to prevent the crash
from occurring in the first place
Active Safety is Job One
The key is
This is active safety
Opportunities in Smart Safety Systems
The key is
UNIT II
Automotive Safety Continuum

Phase 1: Avoid problem
situations.

situations.
Phase 2: Maintain control
if trouble begins

situations.
if trouble begins
Phase 3: Protection when the

crash is unavoidable

situations.
if trouble begins
Our Focus Should be

Crash Avoidance
Improved Safety Through Functional Integration
Driver
Springs
Struts
Steering
Tires
Chassis Mounts
Electronics
Brakes
Networking Active and Passive

Technologies Will Improve Safety
Accident preventing systems
(Global Chassis Control)
Stability management systems

(Electronic Stability Program, Roll Stability
Control, Electronic Stability Program II)
Electronic brake systems

(Anti-lock Brake Systems, Traction Control
Systems, Brake Assist)
Hydraulic brake systems

(brake caliper, brake booster, etc.)
Active Safety
Accident prevention
Networking Active and Passive

Technologies Will Improve Safety
Goal:
A vehicle that prevents
accidents and injuries
Accident preventing systems
Injury preventing systems
(Global Chassis Control)
(OOP, CV)
Stability management systems

(Electronic Stability Program, Roll Stability
Control, Electronic Stability Program II)
Intelligent restraints
(Satellites, PRP)
Electronic brake systems
Electronic restraints
(Anti-lock Brake Systems, Traction Control

Systems, Brake Assist)
(Airbags, seatbelt tensioner,..)
Hydraulic brake systems
Mechanical restraints
(brake caliper, brake booster, etc.)
(seatbelts,..)
Active Safety
Accident prevention
Passive Safety
Injury prevention
Continental Brings together Know-How in

Tires, Electronics and Brake and Chassis
Tires
Electronics
Brake & Chassis
Full Circle
Before:
the industry needs to do more
on the safety front
Full Circle
Before:
the industry needs to do more
on the safety front
Now:
we need to do more to make our
technology better understood and
sought after in the new vehicle marketplace
Our Challenge: Make Consumers

More Aware of Active Vehicle Safety
Develop public awareness

of these possibilities to engineer a
miss
Get them to buy them!
J.D. Power & Associates Survey

Ranked Stability Control among Top
10 Desired Features
ESC Helps Save Lives

Recent study by Mercedes indicates Electronic Stability
Control can reduce single vehicle crashes by 30%
30% reduction in the U.S. could save more than 5,000 lives
Same Mercedes study indicated total crashes for vehicles
equipped with Electronic Stability Control were reduced by
15%
Would save American public almost $35 billion
Would pay for the cost of installing Electronic Stability
Control on all vehicles built in the U.S. some 7-9 times
Bottom Line in the Mercedes Study:

There was a clear drop in
the accident rate after
standard installation of
electronic stability control
Electronic Stability Control

Helps Drivers Avoid Crashes
- In Japan Toyota Study shows 35% reduction in single-vehicle

crashes: could save more than 6,000 lives a year
30% reduction in head-on crashes could save
another 2,500 lives per year
50% reduction for more severe accidents
Confirms Mercedes conclusion that electronic
stability control is more effective in the higher speed
ranges where vehicle dynamics play a greater part
and where crashes that do occur are more severe
Electronic Stability Control

Recommended For All New Vehicles
- In Sweden Swedish National Road Administration Study:

Electronic stability control found to reduce
accidents with personal injuries
Electronic stability control should be
implemented in new cars ASAP
Consumers should be advised to choose cars
with electronic stability control, especially in
countries with wet and icy roads
Electronic Stability Control Saves Lives

With fatalities overcoming the safety gains
from seat belts and air bags (both passive
systems), its now the critical time for the
industry to embrace ACTIVE safety systems
like electronic stability control. Using proven
technology to save lives is a necessity
Raising Consumer Awareness
www.esceducation.org
www.drivesaferamerica.org
Are We Ready?
The Technology to Help Drivers Avoid Crashes
Altogether and Make all Vehicles Safer is Within
Our Grasp
Active Vehicle Safety Saves Lives

We are the frontier of a revolution in active vehicle safety
Technology to save lives, help prevent rollovers and reduce crashes is here
today ESC
Electronic stability control is as important to safety as airbags, ABS or seatbelts
Several recent independent studies from Europe and Asia prove electronic
stability control saves lives and reduces crashes and their severity
Electronic stability control helps avoid crashes before they happen
Actively preventing accidents significantly reduces the number of injuries and
will save thousands of lives annually
This proven technology is available to the North American driving public today,
but most consumers are still unaware it exists
UNIT III
INTRODUCTION
AERODYNAMICS :
Study of forces generated by motion of air on moving body.
CLASSIFACATION OF AERODYNAMICS :
external and internal, subsonic , supersonic , hypersonic
FIELDS OF APPLICATION :
aerospace engineering, design of automobiles , ships , civil
engineering , design of bridges etc.
AERODYNAMIC FORCES ON A BODY

LIFT
(DOWNFORCE)
DRAG
WEIGHT
THRUST
HISTORY OF EVOLUTION OF
AERODYNAMICS IN CARS
DESIGNS IN EARLY 20th CENTURY :

cars with low speeds, no aerodynamic problems.
CARS IN THE EARLY 50s :

cars designed for big familys , complete negligence
of aerodynamics.
CARS AFTER 70s :

fuel crisis , need of economic designs , evolution of aerodynamics.
WHY WE NEED TO IMPROVE

AERODYNAMICS IN CARS
SPEED
better aerodynamics higher will be the speeds.
FUEL EFFICIENCY
better aerodynamics , less work for engine.
Aerodynamics to make the efficient

even more efficient!
Mythbusters Tailgait down or up?
Mythbusters Tailgait down or up?
AERODYNAMICS IN MCLAREN
F1
SPECIFICATIONS
FRONT END
REAR END
SCOOPS
WINGS
Mclaren F1
AERODYNAMIC DEVICES
SPOILERS
NACA DUCTS
Increase rate of flow
To expose air to areas not exposed to direct air
flow.
METHODS TO EVALUATE AERODYNAMICS IN

CARS
WIND TUNNELS
Research tool to study effect of air moving over
a solid object.
Trial and error process.
Special pressure paints for analysis.
Detailed analysis of air flow patterns.
Analyzing for the optimal design.
AERODYNAMIC IMPROVEMENTS IN THE

CAR THAT WE ALREADY OWN
Keep your vehicle washed and waxed

Remove mud flaps behind wheels
Place license plate out of air flow
Avoid roof-racks or carriers
Close windows, close sunroof
CONCLUSION
Aerodynamics in cars is a factor in the over all
performance of the car, it should never be
compromised.
UNIT IV
Back
Back
Back
FRONT END
FRONTAL PRESSURE
PRESSURE DIFFERENCE
MINIMISE FRONTAL AREA
REDUCE cd
Back
SCOOPS
ENGINE COOLING
INCREASESFLOW
RATE OF AIR
Back
REAR END
REAR VACUM
FLOW DETACHEMENT
TURBULANCE
Back
WINGS
PRODUCE
DOWNFORCE
REDUCE DRAG
Back
Back
Back
COEFFICIENT OF DRAG
Drag = 1/2xd x Cd x A Xv2
Measure of aerodynamic
efficiency.
Back
SPECIFICATIONS
EngineType:V12
Curb Weight : 1100 kg.
Displacement:6064 cc
Horsepower:627 bhp @ 7400 rpm
Torque:479 lb-ft @ 4000 rpm
Performance0-60 mph:3.2 sec
0-100 mph:6.3 sec
Top Speed:240 mph /hr
BACK
Some Background...
Cars at first were built entirely of wood, and later of
wood frames with steel body panels.
In the early 1900s, the idea of a body-on-frame
design came about.
These vehicles had
a load-bearing chassis
that supported all the
mechanical parts
and a body usual made
of steel.
Ford Model T
Courtesy Car Body Design
http://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php
Moving Forward...
Honda Civic Frame
http://automobiles.honda.com/images/2009/civic-sedan/safety/safety-header.jpg
Today, most smaller

vehicles such as small
SUVs and sedans use a
unibody (or monocoque)
construction.
Heavy-duty vehicles like trucks and busses still use

the idea of body-on-frame.
Regardless of the construction technique, steel is still
the predominant material used in automotive frames.
A Quick Comparison
Typical Ladder Frame

Monocoques
What
its allin About
Today, the new
revolution
car design is the use
of new materials in the vehicle structure.
As fuel economy restrictions become tighter,
manufacturers must find new ways to meet them.
This has led them away from using so much steel
in the vehicles, and more and more are moving
towards aluminum.
The central theme of our project was to compare
these new lightweight aluminum cars to their steel
predecessors and see if anything is being
sacrificed and/or gained.
A Basic Comparison
Two common alloys used in car manufacturing:
For Aluminum: AA 5182
For Steel: AISI 1020
Steel
Al
Yield
Strength
(MPa)
294.8
395
UTS (MPa)
394.7
420
Hardness
(HB500)
104
58
Data Courtesy efunda
http://www.efunda.com/materials/alloys/carbon_steels/show_carbon.cfm?ID=AISI_1020&prop=all&Page_Title=AISI%201020
http://www.efunda.com/materials/alloys/aluminum/show_aluminum.cfm?ID=AA_5182&show_prop=all&Page_Title=AA%205182
Properties
Density of Steel: 7.88 g/cm3
Density of Aluminum: 2.7 g/cm3
Aluminum is about 3 times lighter than steel per
unit volume, but can be made just as strong using
certain alloys/shapes/bonding methods.
Because of this, AL parts can be thicker, and thus
stronger, than their steel counterparts, all while
weighing less.
The Cost Issue
While Al may seem like a miracle metal for car

production, there is a reason not all cars are made
from Al... It costs a lot more than Steel.
The Move to Aluminum
The first production vehicle to move to an Al frame

was the Audi A8 in 1994.
This allowed Audi to make their full-size car lighter
than the competitions (BMW, Mercedes,Lexus...), thus
giving them the edge in performance & handling.
This comes at a price premium though, for instance
compared to a Lexus LS460 (Steel framed) which costs
around $65,000. The A8 starts at $75,000
Audi A8
Lexus LS460
An Increasing Trend
http://www2.prnewswire.com/mnr/duckerworldwide/37515/
Cars Utilizing Al Frames
Weight to using aluminum

The most obvious advantage
in place of steel in cars is aluminum weighs less.
Cars with Mostly Al

Space Frames
Safety
Not too many safety tests
have been performed on
Al framed vehicles due to their usually higher price.
However, the Audi A2 is an inexpensive compact car
that has been tested, and received overall favorable
reviews compared to its steel bodies counterparts.
Some other advantages...
There are some manufacturing

methods that can only be done with
aluminum, such as extrusions.
These extrusions allows the Al
Space Frame to have about half the
amount of parts as a traditional steel
monocoque.
Because of all this, Al is already a
cheaper material to use for low
volume production cars (under
100,000 units a year or so).
A Few Other Facts...

Today, the average car contains about 200
pounds of aluminum parts.
Aluminum space frames (like that from Audi),
contain fewer parts and fewer connection
nodes, which helps keep production costs
lower.
UNIT V
In The Future
http://andrewbeard.wordpress.com/2009/05/11/technology-carbon-fiber-monocoque-chassis/
While Aluminum may be the wave of the future for

now, some exotic car companies are already looking
ahead to composite materials.
Take for example Porsche Carrera GT, which used a
completely Carbon-Fiber monocoque construction in
addition to Carbon-Fiber body panels.
Because of this, the curb weight of the car was only
3000 lbs., even with a 5.7L V-10 engine powering it.
Porsche CarreraDriving
GTIntelligence
http://upload.wikimedia.org/wikipedia/commons/thumb/6/65/Porsche_Carrera_GT_-_Goodwood_Breakfast_Club_
%28July_2008%29.jpg/800px-Porsche_Carrera_GT_-_Goodwood_Breakfast_Club_%28July_2008%29.jpg
References
Building an aluminum car
http://www.allbusiness.com/professional-scientific/scientific-research-development/443897-1.html
History of Automobile Body and Chassis

http://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php
Automobile Bodies: Can Aluminum Be an Economical Alternative to Steel?

http://www.tms.org/pubs/journals/JOM/0108/Kelkar-0108.html
Different Types of Chassis

http://www.autozine.org/technical_school/chassis/tech_chassis2.htm
Aluminum Versus Steel

http://www.travistrailer.com/public/pag16.aspx

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Vehicle Body Engineering

Active Vehicle Safety Systems Save Lives

Our Industry is Under Siege

Crashes Cost Americans $230 Billion

$230.6 billion economic cost to society

The Motor Vehicle Safety

Electronic Stability Control Improves Safety

We Have Safety Technology Today to Make

The Bottom Line

Make the chassis itself

Raise comfort and safety to new

Passive Safety is Job Three

The next frontier is

Active Safety is Job One

This is active safety

Opportunities in Smart Safety Systems

Automotive Safety Continuum

Automotive Safety Continuum

Automotive Safety Continuum

Phase 3: Protection when the

Automotive Safety Continuum

Our Focus Should be

Improved Safety Through Functional Integration

Networking Active and Passive

Stability management systems

Electronic brake systems

Hydraulic brake systems

Networking Active and Passive

Injury preventing systems

(Global Chassis Control)

Stability management systems

Electronic brake systems

(Anti-lock Brake Systems, Traction Control

(Airbags, seatbelt tensioner,..)

Hydraulic brake systems

(brake caliper, brake booster, etc.)

Continental Brings together Know-How in

Brake & Chassis

Our Challenge: Make Consumers

Develop public awareness

J.D. Power & Associates Survey

ESC Helps Save Lives

Bottom Line in the Mercedes Study:

Electronic Stability Control

- In Japan Toyota Study shows 35% reduction in single-vehicle

Electronic Stability Control

- In Sweden Swedish National Road Administration Study:

Electronic Stability Control Saves Lives

Raising Consumer Awareness

Active Vehicle Safety Saves Lives

AERODYNAMIC FORCES ON A BODY

DESIGNS IN EARLY 20th CENTURY :

CARS IN THE EARLY 50s :

CARS AFTER 70s :

WHY WE NEED TO IMPROVE

Aerodynamics to make the efficient

Mythbusters Tailgait down or up?

Mythbusters Tailgait down or up?

METHODS TO EVALUATE AERODYNAMICS IN

AERODYNAMIC IMPROVEMENTS IN THE

Keep your vehicle washed and waxed

Today, most smaller