ARMIET ASMIT M B

MODULE-5

BODY ENGINEERING & CHASSIS

ARMIET ASMIT M B
Q.1) Importance of Body design.

Ans.

1. Vehicle body is a superstructure.

2. Body is either integral with the under frame or bolted to the frame. The body &
chassis make complete vehicle.
3. Primary function is to provide protection to engine parts and passengers in case of
front end collision.
4. On other hand, the automobile body design play an important role in view of
structural performance.

Following considerations must be fulfilled by vehicle body.

• It must be lighter.
• It should not have too many and complicated components.
• It must ensure a easy entry and exit.
• It must withstand uniform induced stressed.

Q.2) Materials for body Construction.

Ans.

1.STEEL:-

1. The main factors of selecting material specially for body is wide variety of
characteristics such as thermal, chemical or mechanical resistance, ease of
manufacture and durability. So if we want to choose a material with these
characteristics, Steel is there first choice.
2. There was many developments in irons and steels over the past couple decades that
made the steel more light-weight, stronger, stiffer and improving other performance
characteristics.
3. Include not only vehicle bodies, but also engine, chassis, wheels and many other
parts. Iron and steel form the critical elements of structre for the vast majority of
vehicles, and are low-cost materials.
ARMIET ASMIT M B
2.Aluminum:-

1. There are a wide variety of aluminium usage in automotive powertrain, chassis and
body structure. Use of aluminium can potentially reduce the weight of the vehicle
body. Its low density and high specific energy absorption performance and good
specific strength are its most important properties.
2. Aluminium is also resistance to corrosion. But according to its low modulus of
elasticity, it cannot substitute steel parts and therefore those parts need to be re-
engineered to achieve the same mechanical strength, but still aluminium offers
weight reduction.

3.Magnesium:-

1. Magnesium is another light metal that is becoming increasingly common in

automotive engineering. It is 33% lighter than aluminium and 75% lighter than
steel/cast iron components.
2. Magnesium alloys have distinct advantages over aluminium that include better
manufacturability, longer die life and faster solidification. Also magnesium
components have higher machinability.

4.Advanced composite materials:-

1. Fibre reinforced composites offer a wide range of advantages to the automotive

industry. It has the potential for saving weight offered by their low density.
2. 2.Component designs can be such that the fibres lie in the direction of the principal
stresses, and amount of fibre used is sufficient to withstand the stress, thus
optimising materials usage.

5. Glass-fibre composites:-

1. Glass fibre is being used mostly for the sports car which includes Formula 1 cars.
2. It is lighter than steel and aluminium, easy to be shaped and rust-proof. And more
important factor is that it is cheap to be produced in small quantity.
ARMIET ASMIT M B
Q.3 Styling Forms of Cars.

Ans. Automobiles body style are highly variable, some body style remains in production
while other becomes less common or obsolete.

1. Buggy:- A buggy is an automobile with wheels that projects beyond the vehicle body.
2. Cabrio Coach:- A form of car roof, where a retractable textile cover amounts to a large
sunroof.
3. Cabriolet:- A body style with flexible textile roof or rigid retracting roof with highly
variable design detail, that can convert between open hair and enclosed modes.
4. Coupe:- A 2-door, 2 seater car with a fixed roof. Its doors are often longer than those
of an equivalent sedan and the rear passenger area smaller, the roof may also be low.
5. Hatchback:- The engine compartment cover its bonnet, the trunk is at the rear.
Hatchback sedans are known simply as hatchbacks incorporates a shared passenger
and cargo volume, with rearmost accessibility via a rear fifth door, typically a top
hinged lift gates and features such as fold down rear seats to enable flexibility within
shared passenger volume.
6. Minibus:- It is designed to carry fewer people than a full size bus, generally upto 16
people in multiple rows of seats. Passenger access in normally via a sliding door on
one side of the vehicle.

Q.4 Bus Body Styles

Ans

Type A
1. This are the smallest type of bus built on cutaway van chassis.
2. It has single or dual rear wheels on drive axle.
3. The entrance door is mounted behind the front wheels.
4. At least 10 passengers can seat and maximum 16 passengers.
ARMIET ASMIT M B
Type B
1. Type B buses are larger and heavier than type A buses while still smaller than type C
and D buses. Type B buses are less common produced today than in the past.
2. A bus body is mounted on a stripped chassis.
3. The entrance door is mounted behind the front wheels.
4. Maximum 36 passengers can seat.
Type C
1. These are the most common large buses, as such, these have become the most
synonymous with the depiction of large bus in photography, film and television.
2. A bus body is mounted on cowled medium duty truck chassis.
3. The entrance door is mounted behind the front wheels.
4. The engine is mounted forward of the windshield.
Type D
1. This is the largest bus type.
2. A bus body is mounted on a separate chassis.
3. The entrance door mounted in front of the wheels.
4. The engine is mounted next to the driver cabin inside the bus, in the rear of the bus
behind the rearmost seats, or in between the axles underneath the floor.
Q5. Lay out of passenger bus
Ans. Chasis is a main structure, upon which all the major component of an automobile
which are..necessary to proper the vehicle are assembled. Chasis comprises of everything
of a vehicle except the body, cabin & equipment. The automobile chassis consist of
following components:
ARMIET ASMIT M B

1. Frame:- It is a skeleton to hold the major unit together There are of two types:
a)The conventional pressed steel frame to which all mechanical unit are
attached.
b) Integral or frameless construction in which body construction perform
combine function of body & frame. So, it decreases the weight & save fuel
consumption also reduces manufacturing cost but increases repair cost if
damage occur during accident.
2.Engine – It provides motive power to perform the various function of vehicle.
3. Transmission System - It consists of clutch, gearbox , universal joint, propellers shaft,
differential, rear axle, wheel.
4.Suspension System - This system isolates the vehicle body from the road shock which
are in the form of rolling, bouncing & pitching. It provides comfort to passenger.
5.Controls- Vehicle includes steering system, braking system & engine control.
6. Electrical control: This system consists of supply systems Battery & dynamo starting
relay, ignition system (Battery or magneto-ignition system), other miscellaneous system
like driving light signaling, reverse ,light, panel light, wiper ,etc.
7. Radiator: It is advice used to recool the hot engine cooling water for recirculation
purpose. The radiator is connected to engine by base pipe to allow the cooled water
circulation.

Q.6 Lay out of passenger cars. [Same ans for Power plant location][ if asked for 5
marks just draw figure and give description of engine location and type of drive.]

Ans. Normally car manufacturers tend to make their cars have an equal weight
distribution for each wheel. The overall best weight distribution helps the car for good
acceleration, braking and steering.

1.Front Engine Rear Wheel Drive :

1. Rear wheel drive places the engine in the front of the vehicle and the driven wheels
are located at the rear, a configuration known as front-engine, rear-wheel drive
layout.
2. In this layout a front mounted engine-clutch-gear box unit drives a beam type rear
axle supported on leaf springs through a propeller shaft with two universal joints.
3. With the help of coil springs, the front Wheels are independently sprung.
ARMIET ASMIT M B

REAR AXLE
RADIATOR

ENGINE CLUTCH GEAR BOX

Some of the advantages provided by this system are :

1. Even weight distribution: Balanced weight distribution between the front and
the rear wheels providing good handling characteristics.
2. Large luggage space is provided behind the rear seat.
3. Maintenance and accessibilitv of engine, gear box is easy and the control over the
accelerator, clutch, choke simple.
4. Radiator cooling is natural (by air) so decreases the power required for cooling.
Disadvantages :

1. Reduces back seats leg room space,

2. A tunnel is needed for the propeller shaft,
3. Reduces boot space,
4. Heavier and more expensive.
5. If stuck in mud or snow it is harder to drive away than in a front wheel drive car .

2. Rear Engine Rear Wheel Drive :

1. This layout consists of placing the engine, clutch and gearbox in the back. So taking
the space of the boot. In these type of layout more than 50% of the weight is on
rear axle.
2. The necessity of the propeller shaft is completely eliminated. The clutch, gear box
and engine and final drive form a single unit.
ARMIET ASMIT M B

Advantages :

1. Excellent traction is available while climbing hills.

2. Very compact and accessible power and transmission assembly is provided.
3. Lot of weight at the back improves acceleration and braking, rear wheels and disc
brakes can be designed to take a bigger amount of braking due to the weight
distribution to the rear end.
4. Front of the vehicle provides good visibility and by designing the body to
aerodynamic shape gives good streaming lining.
Disadvantages :

1. At high speed, relatively high proportions of weight at the rear axle will make the
car unstable at speed. There is a strong tendency for the vehicle to oversteer.
2. Space utilized for engine compartment is wasted.
3. Difficulties with the arrangement of the engine cooling system. Natural cooling of
radiator is not possible. Power requirement increases. Compact engine, clutch and
gearbox make servicing more difficult.
4. The wheels gets turn too sharply due to tendency of the vehicle to over steer. This
necessitates the turning of the steering wheel in the opposite direction to make the
correction by driver.
ARMIET ASMIT M B
3. Front Engine Front Wheel Drive :
1. Engine, clutch, gearbox and final drive build together to form a single integral
assembly. Normally transversal engine arrangement is used.
2. Longitudinal mounted engine is the other possible layout. Weight distribution tends
to be more than 50% in the front axle.

Advantage

1. This type of arrangement provides optimum passenger space and a flat floor line
resulting in a transverse underfloor-longitudinal engine position.
2. The propeller shaft length is reduced or neglects the propeller shaft.
3. Good grip with road surface due to engine weight at front.

Disadvantage

1. Difficulty in hill climbing because weight move backwards.

4. FRONT ENGINE ALL WHEEL DRIVE

ARMIET ASMIT M B
In this arrangement all the four wheels of the vehicle are driven by the engine thus making
the entire vehicle weight available for traction.

Advantage.

1. Traction is nearly doubled.

2. Handling characteristics in normal condition can be configured to emulate FWD or
RWD.
3. Gives sufficient power and superior engine braking on loose surfaces.

Disadvantage.

1. The manufacturing cost is high .

2. More component and complicate transmission.
3. Increase power trains mass and power transmission loss.

5. Mid engine all wheel drive.

This type of engine layout places the engine between the two axles and the rear wheels
are driven.

Advantage.

1. Good acceleration due to back weight transfer.

2. Good braking and neutral handling.
3. Front of the car can be aerodynamically optimized.
ARMIET ASMIT M B
Disadvantage.

1. When accelerating some steering is lost.

2. Takes a lot of space.
3. No back seats and difficulties in cooling system.

Q.7) What are open, semi integral and integral vehicle structures? State Their
application and advantages.

Ans. Open Integral Structure:- 1.In the open vehicle structure, the loads on the vehicle
are transferred to the suspension system entirely by a separate chassis.

2.In this case, the body work either being made of very flexible material and being made
stiff.

3.The body is isolated from the chassis defection rubber mounting. In this case, the vehicle
load concentrated round the mountings & hence results in early failure.

Applications:-

Cars

Trucks

Advantages

This design offers good beam resistance because of its continuous rails from front to rear.
ARMIET ASMIT M B
B. Semi Integral Structure:- 1.In this type of frame load is transferred to the body
structure also this Frame however is heavy.

2 In semi integral frame half frame is fixed in the front end on which engine gear box and
front suspension is mounted.

3. In this structure, the body mounts are made of stiff material. The body structure has
now become semi integral.

4.Styling form of body changes & eliminates road noise by proper insulation.

Applications:-

In European cars

Advantages:-

When the vehicles is met with the accident the front frame can be easily taken to replace
the damaged chassis frame.

C. Integral Structure:- 1. In this type of construction there is no frame and all assembly
units are attached to the body.

2 The chassis , floor and body are assembled by from a large number of mild steel
pressings.

3 In the structure, the longitudinal & cross members of the chassis were incorporated into
the frame work of the load carrying body.

4.With this arrangement part of the load previously carried by the chassis, is diffused
through the body structure. This aspect eliminates heavy chasis members that ought to
carry the full bending load

Applications:-

All modern cars

Advantage:-

Due to elimination of long frame it is cheaper and due to less weight most economical also.
ARMIET ASMIT M B

Q.8) Explain Normal Control, Forward control and semi forward control chassis
layouts.

Ans. 1. Automotive chassis is skeletal frame on which various mechanical parts like
engine, tyres, axle assemblies, brakes steering etc, are bolted.
2.At the time of manufacturing, the body of a vehicle is, flexibly molded according to
structure of chassis.
3.Automobile chase helps keep an automobile rigid, stiff & unbending. Auto chassis.
ensures low levels of noise, vibrations & harshness throughout the automobile.
Classification of chassis on the basis of control chassis is following:
i) Normal control chassis
ii) Forward control chassis
iii) Semi-forward control chassis
i) Normal control cháis:
Engine is fitted in front of driver cabin or driver seat such as in cars. Chassis portion
cannot be utilised for carrying passengers & goods.

ii) Semi forward control chassis:

Half-portion of the engine is in driver cabin and remaining half is outside the cabin such as
in Tata trucks. In this arrangement, a part of the chassis is utilized for carrying extra
passengers.
ARMIET ASMIT M B

iii) Forward control chassis:

Complete engine is mounted inside the drive cabin. Driver seat is just above the front
wheel.

Q.9 what is the function of chassis frame and giveLoad on chasis frame.

Ans. Functions

1. To carryall the stationary loads attached to it and loads of passenger

and cargo carried in it .

ARMIET ASMIT M B
2. To withstand torsional vibration caused by the movement of the vehicle

3. To withstand the centrifugal force caused by cornering of the vehicle

4. To control the vibration caused by the running of the vehicle

5. To withstand bending stresses due to rise and fall of the front and rear

axles

The loads acting on the chassis frame are as follow

1. Stationary loads namely the loads of permanent attachment like all

the parts of the chassis, body etc.

2. Short duration loads while turning , braking etc.

3. Momentary loads while quick acceleration , sudden braking etc.

4. Loads applied while crossing roads of irregular and uneven surfaces

5. Loads caused by sudden accidents, head on collusions etc.

6. Loads caused by irregular and overloading of vehicle.

Q.10 Load distribution of structure.

Ans.

1. The complete structure of an automobile is subjected to many and varied stresses.

2. When a motor vehicle is at rest, the stresses to which its frame members are
subjected are chiefly due to vertical bending moments.
3. In motion, these stresses are modified and considerably increased as a result of
road shock. Bending moments reach their maximum value when there both front or
both rear wheels pass over an obstacle at speed of shock with a large vertical
component is imparted to the adjacent corner of the frame. This causes the frame to
twist or deflect torsionally.
4. When one of the front wheel runs up against the major obstruction, a nearly
horizontal shock may be imparted to it. This shock is transmitted to axle and spring
to the side Rail on that side.
ARMIET ASMIT M B
5. Then the frame has a tendency to weave. Modern passenger car frames with
substantial X members are well able to take shock of this type. But no frame can
withstand a major collision without damage.
6. Hence correct frame alignment is essential for proper tracking of front and rear
wheel.