Unit 1 Introduction Automobile

Engineering

Prof. Praveen P. Rathod

Praveen.rathod@viit.ac.in
Department of Mechanical Engineering

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
Teaching Scheme: Credits:
•TH: -- 03 hrs/week
TH:--03

•PR.: - 02 hr/week OR:-- 01

Examination Scheme:
Insem-30
Endsem-30
CE-20
Competency Skill: -20
11/08/2021
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 DEFINITION

• Automobile engineering is a branch of engineering which deals with

everything about automobiles and practices to propel them.

• Automobile is a vehicle driven by an internal combustion engine and

it is used for transportation of passengers and goods on the ground.
Automobile can also be defined as a vehicle which can move by itself.

• Examples : Car, jeep, bus, truck, scooter, etc.

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Department of Mechanical Engineering, VIIT , Pune-48
 History of Automobile

The first car was built by Joseph Cugnot in 1769. It was powered by a steam engine and
was very slow.

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First Car

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History of Automobile
• The first car was built by Joseph Cugnot in 1769. It was powered
by a steam engine and was very slow.

• Jean Joseph Étienne Lenoir was the first to build the one cylinder
engine, internal-combustion engine, was later patent.

• Nikolas August Otto built the first four cylinder engine.

• In 1886 Gottlieb Daimler designed the first four wheeled

automobile. They also created the first v-slanted engine.

• Karl Benz, know as one of the founders of Mercedes-Benz, is the

first to build an automobile powered by an internal combustion
engine.
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Benz Patent-Motorwagen

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History of Automobile

• The first hybrid commercial truck was built in 1910, and as

the gasoline engine was refined interest in hybrids died
down.

• As problems with environment and gas process continue,

Hybrids are now a hot commodity in the market place and
are now the new wave of future cars

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 History of Automobile
• Gottlieb Daimler and Wilhelm Maybach with Benz’s
manufacturing firm in 1926 to create Daimler-Benz. The joint
company makes cars today under the Mercedes-Benz
nameplate, and Daimler Chrysler

• Henry Ford, a famous car company founder, designed the

world’s biggest car manufacturer, manufacturing over 15
million Model by 1927

• Hybrid cars have also been around since the 1900’s.

• In the 1900’s Ford made more steam and electric cars than it
did gasoline.
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 Landmark of Indian automobile industry

•1897 First Person to own a car in India - Mr. Foster

of
M/s Crompton Greaves Company, Mumbai
•1901 First Indian to own a car in India - Jamsetji Tata
•1905 First Woman to drive a car in India - Mrs.
Suzanne RD Tata
•1905 Fiat Motors
•1911 First Taxi in India
•1928 Chevrolet Motors
•1942
•
Hindustan Motors
•
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 Landmark of Indian automobile industry
• 1944 Premier Automobiles Limited
• 1945 Tata Motors
• 1947 Mahindra & Mahindra Limited
• 1948 Ashok Motors
• 1948 Standard Motors
• 1974 Sipani Motors
• 1981 Maruti Suzuki

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 The automobile industry in India
• 6 th largest automobile industry and 4th in terms of sell
• 2 nd largest two-wheeler market.
• 6 th largest Passenger Cars producers.
• 4 th largest in Heavy Trucks.
• 2 nd largest tractor manufacturer.
• annual production of over 2.3million units.
• The monthly sales of passenger Cars in India exceed 100,000units

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Department of Mechanical Engineering, VIIT , Pune-48
COMPONENTS OF AUTOMOBILE
COMPONENTS OF AUTOMOBILE

•1 The basic structure

•2 Power Plant
•3 Transmission System
•4 Accessories
•5 Controls
•6 Super Structure

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Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Basic Structure of a
Automobile
Frame
Suspension
Axle
Wheel

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 Frame

Conventional Frame less

Conventional pressed frame The body is designed in

structure is prepared and all such a way that function of
mechanical components Body and frame is combined
Are attached to it and then and units are attached.
body superimposed
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Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Axle

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Department of Mechanical Engineering, VIIT , Pune-48
Chassis

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Department of Mechanical Engineering, VIIT , Pune-48
 Frame
Frame is the basic unit to which various components are
attached and body is bolted to the frame.
Functions
1 To support the chassis components and the body
2 To withstand static and dynamic load without
deflection

Loads on the frame

1 Weight of the vehicle and passenger

2 Vertical loads when the vehicle comes across a
bump
3 Loads due to road camber, side wind while taking a
turn Department of Mechanical Engineering, VIIT , Pune-48
4 Sudden impacts loads during a collision
5 Load due to engine torque and braking torque
Material for frame
Mild sheet steel, carbon sheet steel, sheet nickel alloy
steel

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VARIOUS LOADS ACTING ON THE
FRAME:

1. Short duration Load - While crossing a broken

patch.
2. Momentary duration Load - While taking a curve.
3. Impact Loads - Due to the collision of the vehicle.
4. Inertia Load - While applying brakes.
5. Static Loads - Loads due to chassis parts.
6. Over Loads - Beyond Design capacity.

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Chassis frame

Cross members

Longitudinal members

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Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
TYPES OF CHASSIS FRAMES:
THERE ARE THREE TYPES OF FRAMES
1. CONVENTIONAL FRAME
2. INTEGRAL FRAME
3. SEMI-INTEGRAL FRAME

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CONVENTIONAL FRAME
a.Channel Section - Good resistance to bending

b. Tabular Section - Good resistance to Torsion

c. Box Section - Good resistance to both bending and

Torsion

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 Conventional Chassis

Affects visibility
of driver

Engine is fitted in front of the driver cabin or driver seat such as

in cars.
Chassis portion can not be utilized for carrying passengers
and goods
Heavy Engine can be fitted, which can used to give more
power
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 Semi Forward Chassis

• Half portion of the engine is in the driver cabin & and

remaining half is outside the cabin such as in Tata trucks /
Tempos

• In this arrangement a part of the chassis is utilized for

carrying extra passengers

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 Forward Chassis

• Complete engine is mounted inside the driver cabin, Driver seat

is just above the front wheel.

• More Boot Space Available as full utilization of chassis

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INTEGRAL FRAME (FRAMELESS)
 used now a days in most of the cars
 no frame and all the assembly units are attached to the
body
 Due to elimination of long frame it is cheaper

 Only disadvantage is repairing is difficult.

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Department of Mechanical Engineering, VIIT , Pune-48
SEMI - INTEGRAL FRAME
 half frame is fixed in the front end on which engine
gear box and front suspension is mounted.
 It has the advantage when the vehicle is met with
accident the front frame can be taken easily to
replace the damaged chassis frame.
 This type of frame is used in FIAT cars and some of the
European and American cars.

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LADDER FRAME:
 The ladder frame is the simplest and oldest of all
designs.
 This design offers good beam resistance because of its
continuous rails from front to rear
o Since two dimensional structure…. Torsional
rigidity is much lower than other chassis especially
with vertical loads or bumps
 One of the oldest form of chassis that is still used by
most of the SUVs till today

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 X type frame
A type frame High torsional rigidity

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SPRINGING SPACE

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Department of Mechanical Engineering, VIIT , Pune-48
Backbone chassis

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● Has a rectangular tube like a backbone and
simple in structure
●
made of glass fibre is used for joining front
and rear axle and responsible for the strength.
● Space within structure used for positioning
drive shaft in case of rear wheel drive.
● Drive train, engine and suspensions are
connected at the ends of the chassis

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Tubular space frame chassis

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● A 3-dimensional design employing number of
circular and square section tubes
● Tubes are positioned in different sections to
provide mechanical strength against forces
from anywhere
● Tubes are welded together and form a
complex structure
● Very strong when compared with ladder and
monococoque chassis of the same weight
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Very strong in any
direction

Very complex, time consuming to built and engages a lot of

space , raise the door sill and results in difficult accessto the
cabin

All ferrari before the 360m ,Lamborghini Diablo, Jaguar

Xj220 ,caterham
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Monocoque chassis

● Most modern cars use this type

● A single piece of frame work that give shape to
the entire car and built by welding several
pieces together
● Demand for monocoque chassis is increased
because it is suitable for robotized production
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• Inherently good crash protection and it is space
efficient and cheap for mass production
• Heavy , impossible for small volume production

• Nearly all mass production cars, all current porche

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Carbon fibre monocoque
chassis

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● Carbon fibre is the most sophisticated
material using in aircrafts, spaceships and
racing cars
● Because of its superior rigidity to weight
ratio
● Several carbon fibres used in motor industry
like Kelvar which has rigidity to weight ratio
among them and can be found in body panels of
many exiotic cars

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CARBON-FIBER MONOCOQUE

 Carbon Fiber is the most sophisticated material

using in aircrafts, spaceships and racing cars
because of its superior rigidity-to-weight
ratio.
 Road cars featuring Carbon-Fiber body panels, such as
Ferrari 288GTO and Porsche 959.There are several
Carbon-fibers commonly used in motor industry.
 Kevlar, which was developed by Du Pont, offers the
highest rigidity-to-weight ratio among them. Because of
this, army's helmets are made of Kevlar. Kevlar can
also be found in the body panels of many exotic cars,
although most of them simultaneously use other kinds of
carbon-fiber in even larger amount.

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CARBON FIBRE MONOCOQUE
Production process
 Carbon-fiber panels are made by growing carbon- fiber
sheets (something look like textile) in either side of an
aluminium foil.
 The foil, which defines the shape of the panel, is sticked
with several layers of carbon fiber sheets impregnated
with resin, then cooked in a big oven for 3 hours at
120°C and 90 psi pressure.
 After that, the carbon fiber layers will be melted and
form a uni-formal, rigid body panel

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Lightest and stiffest
chassis

The most expensive

McLaren F1 ,Bugatti EB110SS, Ferrari F50

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Aluminium space frame
chassis
● ASF consists of extruded aluminium sections,
vacuum die cast components and aluminium
sheets of different thickness
● Highly stressed corners and joints and extruded
sections are connected by complex aluminium
die casting
● 40% lighter yet 40% stiffer than contemporary
steel monocoque
● Its quite complex

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Lighter than steel monocoque and space
effecient

Still expensive for mass production

Audi

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ALUMINIUM MONOCOQUE-
 Audi A8 is the first mass production car featuring
Aluminium Space Frame chassis.

 To replace conventional steel monocoque mainly for

the benefit of lightness.
 Audi claimed A8's ASF is 40% lighter yet 40% stiffer
than contemporary steel monocoque.

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CHASSIS CLASSIFICATION BASED ON ENGINE
LOCATION
 Engine fitted at front
 Engine fitted at Back
 Engine fitted at centre
 Engine fitted at front but crosswise

CHASSIS CLASSIFICATION BASED ON Number of

Wheels fitted in the vehicles and the
number of driving wheels
•4x2 drive chassis vehicle.
•4x4 drive chassis vehicle.
•6x2 drive chassis vehicle.
•6x4 drive chassis vehicle.
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 & DRIVE IS GIVEN TO THE
FITTED AT FRONT
WHEELS FROM THE “REAR”
1. Enough space is available for luggage behind the
rear seat
2. The weight of vehicles is well balance
3. Increased efficiency of cooling system

Engine is fitted at front & drive is given to

front wheel
1. Low floor is available.
2. Vehicle has more road holding capacity.
3. clutch , gear box & differential are usually made
as one unit, thereby cost is reduced.

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ENGINE IS FITTED IN FRONT BUT CROSSWISE:
 BMC
 Maruti

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ENGINE FITTED AT THE CENTRE OF THE
CHASSIS:
 Drive is given to the rear
 As in royal tiger world master buses

 This arrangement provide full space of floor for use

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ENGINE FITTED AT BACK
1. Flat floor is available since long propeller shafts are
eliminated
2. With elimination of propeller shaft the centre of gravity
lowered giving stable driving
3. Better adhesion on road specially when climbing hill.
4. While Climbing hills proper adhesion may be affected since
the weight of vehicles moves to the rear , thereby reducing
the weight on the front wheel.
5. As a result of grouping of the engine with clutch, gear box
and differential, the repair and adjustment become difficult
due to congestion at the rear.

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CARBON FIBRE PANELS
 Where is the carbon-fiber used ? Body panels or Chassis ?
 Since body panels do nothing to provide mechanical strength, the
use of carbon fiber over aluminium can barely save weight.
 The stress member remains to be the chassis, which is
usually in heavier and weaker steel tubular frame.

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 COMPARISON LADDER AND MONOCOQUE
Performance -
 The monocoque is a lighter design which is a plus for fuel efficiency,
 It has more torsional stiffness and is by far the better chassis for performance
oriented vehicles.
 The heavy nature of the ladder chassis makes it tough and it is much better
than the monocoque for carrying heavy loads and towing heavier objects.
Design -
 A unibody bodyshell is difficult to design, build and modify (platform sharing
) when compared to the body on frame but computer aided design (CAD)
makes unibody platform sharing much easier.
 For body on frame vehicles its easy to build another body even from another
bodystyle and place it on a ladder chassis as long as they are of similar
dimensions.
Materials -
 Unitary bodyshells can be made from a variety of materials steel and steel
alloys, aluminium and aluminium alloys and even carbon fiber or
combinations of these materials whereas ladder chassis are usually built from
steel.

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A QUICK COMPARISON

Typical Ladder Frame

Monocoques

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A BASIC COMPARISON
Two common alloys used in car manufacturing:
For Aluminum: AA 5182
For Steel: AISI 1020
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.

Steel Al
Yield Strength
(MPa) 294.8 395
UTS (MPa) 394.7 420
Hardness
(HB500) 104 58
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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.

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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
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CARS UTILIZING AL FRAMES

Audi A8 Honda NSX

Jaguar XJ Audi A2
Corvette Z06 Audi R8
(GM)

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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).

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IN THE FUTURE
 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 (1360 kg), even with a 5.7L V-10 engine
powering it.

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 VEHICLE ATTRIBUTES
Vehicle Attributes Description

Cost Lowest production, assembly and distribution cost compared to

competitive vehicles

Weight Lowest curb weight compared to competitive vehicles in its weight

class

Package Best use of the space to provide comfort and amenities to passengers

Safety 5* crash rating from the Federal Motor Vehicle Safety Standard
(FMVSS)

Dynamics Best ride & handling performance compared to competitive vehicles

Durability Highest reliability and high mileage durability compared to

competitive vehicles

NVH Lowest noise, vibration and harshness compared to competitive

vehicles

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BODY
In case of conventional frame, there must be separate
structure i. e. the body attached to the frame , while in
case of frameless construction the body performs the
function of both.

The body and frame should jointly meet the following

requirements
1 Strength – Body must be strong enough to withstand
all forces.
2 Stiffness – Body must posses sufficient stiffness to
prevent sagging in the middle.

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3 Air drag – The shape of the body should be such
that the air drag is minimum.

4 Space – The should be adequate space in the body

5 Resistance to corrosion

6 Protection against weather

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Department of Mechanical Engineering, VIIT , Pune-48
TYPES OF CARS ON AS PER THEIR DESIGN
1) Sports Cars
 Sports cars are the perfect example of best automobile engineering,
 sports cars are two-seat small cars that are designed for quick
response to move fast for spirited performance and nimble handling.
 Nissan GT-R
 Now a days sports cars have become a first choice for every body,
therefore automobile manufacture are making them more fast and more
luxury.
 Some example of sports car masterpieces are
 Nissan GTR, Lamborghini Veneno, Maserati Alfieri etc.

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2) Multi-utility vehicles: MUVs
 Usually based on either a mid-sized car or mini-van
platform.
 Usually two-wheel drive "people movers". They have higher
ceilings, more storage than a sedan, some of the utility of a
SUV with a similar ride,
 though from a construction standpoint not as robust.

 Great for larger families of 4-5 and comfortable.

In India a good example is the Honda Mobilio

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 MPV Hatchback

Coupe

Convertible limosine

Sedan SUV
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Department of Mechanical Engineering, VIIT , Pune-48
 ANATOMY OF AN AUTOMOBILE
(FRONT WHEEL DRIVE)
STEERING
TYRE TYRE
BRAKE BRAKE

WHEEL TRACK
TRANSAXLE
DRIVE SHAFTS

CLUTCH
ENGINE

BRAKE
SUSPENSION BRAKE
TYRE TYRE

WHEEL BASE
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Front engine front wheel drive
Advantages:- Disadvantages:-

1. No propeller shaft 1. Complicated arrangement

2. Low chassis height 2. Two velocity joints needed
3. Engine pulls the car 3. Decrease of tractive effort
4. Better road adhesion 4. Steering is heavier
5. Produce understeer conditions

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Rear Engine Rear wheel Drive

• Rear-wheel-drive layout places

both the engine and drive
wheels at the rear of the
vehicle.

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 ANATOMY OF AN AUTOMOBILE
(REAR WHEEL DRIVE - 2WD)
STEERING
TYRE TYRE
BRAKE BRAKE

WHEEL TRACK
ENGINE GEAR BOX
DIFFERENTIAL

PROPELLOR
CLUTCH SHAFT - REAR

BRAKE
SUSPENSION BRAKE
TYRE TYRE

WHEEL BASE
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 ANATOMY OF AN AUTOMOBILE
(FOUR WHEEL DRIVE)
STEERING
TYRE PROPELLOR TYRE
BRAKE SHAFT - FRONT BRAKE

TRANSFER
CASE - 4WD

WHEEL TRACK
DIFFERENTIAL
4WD

ENGINE GEAR BOX

DIFFERENTIAL

PROPELLOR
CLUTCH SHAFT - REAR

BRAKE
SUSPENSION BRAKE
TYRE TYRE

WHEEL BASE
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FOUR WHEEL DRIVE

• Advantages • Disadvantages

1 When the front wheels 1 Higher initial cost

falls in to a ditch, they can 2 Running cost is more,
be driven out being power because of additional fuel
driven. consumption
2 More power

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Classification of automobiles

1. Use
2. Capacity
3. Make and model
4. Fuel used
5. Body style
6. Wheels
7. Drive
8. transmission

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Frame – Conventional construction
Frame is the basic unit to which various components are
attached and body is bolted to the frame.

Functions
1 To support the chassis components and the body
2 To withstand static and dynamic load without
deflection

Loads on the frame

1 Weight of the vehicle and passenger

2 Vertical loads when the vehicle comes across a
bump
3 Loads due to road camber, side wind while taking a
turn
4 Sudden impacts loads during a collision
5 Load due to engine torque and braking torque

Material for frame

Mild sheet steel, carbon sheet steel, sheet nickel alloy

steel
FRAMELESS CONSTRUCTION

Body structure is so designed so as to combine the

functions of body and frame, the units normally
attached to the frame then being attached directly to
the body

Advantages of frameless construction –

1 Reduced weight and saving in fuel consumption

2 Lower manufacturing cost
3 Lower body position may be obtained, thus resulting
in increased stability of the automobile.
Disadvantages of frameless construction –

1 Reduction of strength
2 Economical only if adopted in mass production
3 Increased cost of repairs in case of damaged to the
body during accidents.
4 Topless cars are difficult to design with frameless
construction