Unit1 New
Unit1 New
Components of automobile
1. Frame
2. Engine
3. Clutch
4. Gear Box
5. Universal Joint
6. Propeller Shaft
7. Differential
8.Suspension system
9.Steering mechanism
10.Wheels
11.Braking system
12.Fuel tank
13.Silencer
14.Radiator,Battery and Electrical systems.
15. Vehicle body
16. Axles
Operation of Automobile
• When the driver turns on the starter switch, it releases the
electric current from a battery and sets into action an electrical
starting motor which turns a flywheel connected to the engine
crankshaft.
• Immediately when the driver steps on a pedal which controls the
rate of flow of air fuel mixture into the inlet manifold of the
engine.
• During the four strokes or two strokes power is produced in the
engine cylinder.
• The power is transmitted from the piston to crankshaft by means
of connecting rod.
• As the process of stokes repeated over and over again, the
crankshaft is turned continuously – an the engine is running.
• The motion of the crankshaft is transmitted to the rear wheels
through the clutch, gear box and differential.
• Crankshaft is connected to gear box through clutch mechanism
• By means of gear shift lever, the gears of the transmission can be
shifted to suit driving conditions for changing the speed.
• The motion from the gearbox to the differential is transmitted
through a propeller shaft.
• The differential is arranged in the rear axle to permit one rear wheel
to turn faster than the other while turning a corner.
• The rear wheels are directly connected to the rear axle and get motion
as the rear axle turns – and the vehicle is in motion.
• The motor vehicle, is directed by a steering gear which controls the
direction in which the front wheels are pointed.
• The braking system is provided to stop the vehicle to slow it down as
required by the driver.
• The unevenness of road surfaces and the jerks are partially
controlled by front and rear springs, by shock absorbers, by padding
and springs in the car seats, by chassis cross members which
decrease sideways and by distribution of chassis and body weight as
between front and rear wheels.
AUTO MOBILE
An auto mobile is a self propelled vehicle. It is used for the
transportation of the passengers and goods from one place to
another place on the ground.
REQUIREMENT
1.It should be develop power by itself
2. The rate of power development must be easily controlled.
3.There should be an arrangement to transmit the power to
the wheels.
4. An arrangement must exist to continue and discontinue
power flow to the wheels.
5. It should be possible to control or vary the torque.
6.It must have direction control.
7. An arrangement must exist to stop the vehicle while it is
running.
AUTO MOBILE
Types
1. With respect to the purpose
2. With respect to capacity
3. With respect to fuel used
4. with respect to number of wheels
5. With respect to drive of the vehicle
6. with respect to side of the drive
7. With respect to transmission
8. With respect to types of suspension
system
Vehicle Layouts
1. There mainly 4 types of vehicle layouts are
in use today.
Body
Chassis & Frame
Introduction of Chassis
• Chassis is a French term and was initially used to
denote the frame parts or Basic Structure of the
vehicle. It is the back bone of the vehicle. A vehicle
with out body is called Chassis.
• The components of the vehicle like Power plant,
Transmission System, Axles, Wheels and Tyres,
Suspension, Controlling Systems like Braking,
Steering etc., and also electrical system parts are
mounted on the Chassis frame.
• It is the main mounting for all the components
including the body. So it is also called as Carrying
Unit.
CHASSIS
• The various component parts and support systems of a chassis are
– The power unit – Engine – consists of cylinder, piston,
connecting rod, crankshaft, flywheel, inlet manifold,
outlet manifold, cooling system (Radiator), lubricating
system, Fuel Tank, Hydraulic Pipes,
– The power train – consists of clutch, gear box, propeller
shaft, universal joints, differentials gears, rear half
axles.
– The running systems – consists of brakes, wheels, tires,
frame, suspension (Rear Springs, shock absorbers) and
the steering system
– The electrical system – consists of different circuits
such as starting circuit, charging circuit, ignition
circuit, lighting circuit and the horn circuit, Storage
battery and cables.
Chassis – Cont.
• Classification of Chassis
1. According to Fitting of Engine:
• Full forward Chassis
• Semi forward Chassis
Semi forward – Half portion outside & half portion
• Bus Chassis inside driver cabin
• Engine at back Chassis (Eg. Volvo Bus, Tata nano)
• Engine at Centre Chassis (Eg. Royal tiger master bus)
2. According to No of wheels fitted into vehicle:
* 4 x 2 Drive Chassis [has 4 wheels with 2 driving wheels]
* 4 x 4 Drive Chassis [ has 4 wheels with 4 driving wheels]
* 6 x 2 Drive Chassis [ has 6 wheels with 2 driving wheels]
* 6 x 4 Drive Chassis [ has 6 wheels with 4 driving wheels] Bus Chassis – Engine fitted in driver cabin
Classification of Chassis
Advantages
• Easier body repairs.
• Body can be lighter and cheaper to manufacture
• Any type of body can be made in the case of commercial vehicles.
• It is easy and cheap for hand build.
Disadvantage:
Since it is a 2 dimensional structure, torsional rigidity is very much
lower than other chassis, especially when dealing with vertical load
or bumps.
Truck Frames:
• The bus or truck frames have the channel section
longitudinal members parallel to each other.
• These have maximum section at the middle,
reducing progressively towards the ends.
• Cross members of box section are riveted to the
side members and support the radiator, engine and
the central bearing of the propeller shaft.
• The rear cross frames (two numbers) have mounts
for attaching the leaf spring.
• Members may be hot or cold riveted.
• Low carbon steel (0.15% - 0.20% C, Ni, Si, Mn, P
and S) is used for the manufacture of various
members.
Car frame
Car Frame Design:
Two longitudinal members, cross members and an X
member.
Members are made by rolling or pressing methods
Pressing method will give light weight and rigid frame.
To obtain uniform strength for minimum weight, the side
members are tapered in depth at both the ends.
Frame nearer at the front to allow for swinging motion of the
front road wheels due to steering.
An arched shape at the front and rear allows the up and
down movement of the road wheels.
This also lowers the centre of gravity of the car, which giving
comfort to the passenger and stability to the car.
X member (Box or channel section) riveted to the
longitudinal members imparts torsional rigidity to the frame.
Rear engine cars have the backbone frame forked at the
rear to house the engine and gear box.
Advantages of Frameless cars:
• Lighter construction but stronger
• Cheaper when mass produced
• Lesser body rattles and squeaks
• Improved torsional rigidity
• Provides lower centre of gravity imparting comfort and good road
holding characteristics.
Disadvantages of Frameless Cars:
• Lesser Impact resistance
• Repairs are expensive
• Greater Mechanical noises
• Uneconomical if produced in small numbers
Sub Frames:
• Box Sections
• Carries the engine, clutch, gear box, steering, front suspension and brakes.
• Attached to the body with the help of nuts and bolts.
• The twisting and flexing of the body has no effect on the units supported on the
sub frame.
• Advantages:
– Easy maintenance and repairs, owing to easy accessibility of parts attached
to it.
– The weight of the sub frame helps to damp vibrations
– Reduces production time.
Vehicle Construction
Loads on Chassis Frame:
1. Load of Short duration:
Occurs when Vehicle crosses broken patch of road results in LONGITUDINAL TORSION.
2. Combined Loads of moment:
Occurs when negotiating curve, apply brakes, striking a pothole results in BENDING & TORSION.
3. Inertia Loads:
Occurs when applied brake for short period results in BENDING OF SIDE MEMBERS
4. Static Loads:
Due to weight of engine, steering, gearbox etc.
5. Over Loads:
Load on the vehicle beyond the specified design. (Eg.MTC Bus in Peak Hours)
6. Other Loads:
Load due to side wind, cornering force while taking a turn – results in
LATERAL BENDING OF SIDE MEMBERS & Load due to Wheel impact with road obstacles –
results in DISTORTION OF FRAME.
MATERIALS FOR FRAME:
1. Mild Steel sheet,
2. Carbon steel Sheet,
3. Nickel alloy steel sheet
Composition of Nickel Alloy Steel Sheet:
Carbon:0.25-0.35%, Manganese:0.35-0.75%,Silicon-0.30%(Max)
Nickel-3%,Phosporous-0.05%(max) & Sulphur – 0.5%(max)
Vehicle Construction
1.Floor Assembly:
• Made up of pressed steel panels divides front, centre and rear sections usually.
• Metal Strips are welded at floor to provide strength, rigidity.
• Wheel house panel welded to the floor to provide sufficient clearance for wheels.
Vehicle Construction
VEHICLE BODY:
Construction & Components:
2. Cowl Assembly
• Cowl is the front portion of the car and made up of many smaller panel stamping of
sheet metal.
• Windshield frame accommodates wind shield.
• Dash board accommodates different warning & indicating devices.
• Side of the cowl are used for hinges for front doors.
Vehicle Construction
VEHICLE BODY:
Construction & Components:
3. Pillar and Roof assembly:
• Classified as A Pillar, B Pillar and C Pillar in modern cars and Centre (B) Pillar
supports rear doors and hinges.
• Rail roof and centre pillar made up of box section to provide max strength.
• Drip mountings are added to the side of rail roof.
• Rear window, Front Windshields are attached to the roof panel by spot welding.
Vehicle Construction
VEHICLE BODY:
Construction & Components:
4. Quarter Panel: This panel is welded to rear wheel house panel, floor panel and the
rear side of the roof.