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

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Vehicle Body Engineering

G.VIJAY BHASKAR
ASST.PROF
AUTOMOBILE ENGININEERING DEPT

Driving Intelligence

UNIT I

Driving Intelligence

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
Driving Intelligence

Our Industry is Under Siege

Driving Intelligence

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


Driving Intelligence

The Motor Vehicle Safety


Equipment Exists Now to Help
Reduce Crashes and Rollovers
Its Called Electronic
Stability Control
Driving Intelligence

Technology
is our passion but

safety
is our business
Driving Intelligence

Electronic Stability Control Improves Safety

We Have Safety Technology Today to Make


Mobility Safer!
Driving Intelligence

The Bottom Line

Make the chassis itself


electronically intelligent

Raise comfort and safety to new


levels without sacrifices
Driving Intelligence

Passive Safety is Job Three

The next frontier is


to prevent the crash
from occurring in the first place

Driving Intelligence

Active Safety is Job One

The key is
to prevent the crash
from occurring in the first place

This is active safety

Driving Intelligence

Opportunities in Smart Safety Systems

The key is
to prevent the crash
from occurring in the first place

Driving Intelligence

UNIT II

Driving Intelligence

Automotive Safety Continuum


Phase 1: Avoid problem
situations.

Driving Intelligence

Automotive Safety Continuum


Phase 1: Avoid problem
situations.
Phase 2: Maintain control
if trouble begins

Driving Intelligence

Automotive Safety Continuum


Phase 1: Avoid problem
situations.
Phase 2: Maintain control
if trouble begins

Phase 3: Protection when the


crash is unavoidable

Driving Intelligence

Automotive Safety Continuum


Phase 1: Avoid problem
situations.
Phase 2: Maintain control
if trouble begins

Our Focus Should be


Crash Avoidance
Driving Intelligence

Improved Safety Through Functional Integration

Driver
Springs

Struts

Steering
Tires
Chassis Mounts

Electronics
Brakes

Driving Intelligence

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

Driving Intelligence

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

Driving Intelligence

Continental Brings together Know-How in


Tires, Electronics and Brake and Chassis

Tires

Electronics

Brake & Chassis

Driving Intelligence

Full Circle
Before:
the industry needs to do more
on the safety front

Driving Intelligence

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

Driving Intelligence

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!

Driving Intelligence

J.D. Power & Associates Survey


Ranked Stability Control among Top
10 Desired Features

Driving Intelligence

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

Driving Intelligence

Bottom Line in the Mercedes Study:


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

Driving Intelligence

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

Driving Intelligence

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
Driving Intelligence

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

Driving Intelligence

Raising Consumer Awareness

www.esceducation.org

www.drivesaferamerica.org

Driving Intelligence

Are We Ready?
The Technology to Help Drivers Avoid Crashes
Altogether and Make all Vehicles Safer is Within
Our Grasp

Driving Intelligence

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
Driving Intelligence

UNIT III

Driving Intelligence

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.

Driving Intelligence

AERODYNAMIC FORCES ON A BODY


LIFT
(DOWNFORCE)
DRAG
WEIGHT
THRUST
Driving Intelligence

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.
Driving Intelligence

WHY WE NEED TO IMPROVE


AERODYNAMICS IN CARS

SPEED
better aerodynamics higher will be the speeds.
FUEL EFFICIENCY
better aerodynamics , less work for engine.

Driving Intelligence

Aerodynamics to make the efficient


even more efficient!

Driving Intelligence

Mythbusters Tailgait down or up?

Driving Intelligence

Mythbusters Tailgait down or up?

Driving Intelligence

AERODYNAMICS IN MCLAREN
F1
SPECIFICATIONS
FRONT END
REAR END
SCOOPS
WINGS

Mclaren F1
Driving Intelligence

AERODYNAMIC DEVICES
SPOILERS
NACA DUCTS
Increase rate of flow
To expose air to areas not exposed to direct air
flow.

Driving Intelligence

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.

Driving Intelligence

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

Driving Intelligence

CONCLUSION
Aerodynamics in cars is a factor in the over all
performance of the car, it should never be
compromised.

Driving Intelligence

UNIT IV

Driving Intelligence

Back
Driving Intelligence

Back

Driving Intelligence

Back

Driving Intelligence

FRONT END
FRONTAL PRESSURE
PRESSURE DIFFERENCE
MINIMISE FRONTAL AREA
REDUCE cd

Back

Driving Intelligence

SCOOPS
ENGINE COOLING
INCREASESFLOW
RATE OF AIR

Back
Driving Intelligence

REAR END
REAR VACUM
FLOW DETACHEMENT
TURBULANCE

Back
Driving Intelligence

WINGS
PRODUCE
DOWNFORCE
REDUCE DRAG

Back

Driving Intelligence

Back
Driving Intelligence

Back

Driving Intelligence

COEFFICIENT OF DRAG
Drag = 1/2xd x Cd x A Xv2
Measure of aerodynamic
efficiency.

Back
Driving Intelligence

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
Driving Intelligence

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
Driving Intelligence
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.
Driving Intelligence

A Quick Comparison

Typical Ladder Frame


Monocoques

Driving Intelligence

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.
Driving Intelligence

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

Driving Intelligence
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.

Driving Intelligence

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.

Driving Intelligence

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

Driving Intelligence

An Increasing Trend

http://www2.prnewswire.com/mnr/duckerworldwide/37515/

Driving Intelligence

Cars Utilizing Al Frames

Driving Intelligence

Weight to using aluminum


The most obvious advantage
in place of steel in cars is aluminum weighs less.

Cars with Mostly Al


Space Frames

Driving Intelligence

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.

Driving Intelligence

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).

Driving Intelligence

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.

Driving Intelligence

UNIT V

Driving Intelligence

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

Driving Intelligence

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