Basics of automobile

engineering
Automotive?

Automobile?

Automation?
Automotive:- any machine with moving parts

Automobile:- any machine with moving part that

helps in locomotion

Automation :- any machine with moving parts

included in a process.
 Sports car?

Formula car?
Super car?

Concept car?
Sports car:- Mainly for performance and looks.

Formula 1 :- It is a race b/w engineers and these cars are

made just to win race, not for comfort or luxury.

Super car:- Very expensive and fast, powerful car.

Push-type product/ limited edition.

Concept car:- just to show off technology level of a

industry.
 Formula 1 car Sports car

Super car Concept car

Fundamentals of Chassis
What is a CHASSIS:-
Chassis:- Fully functional and movable unit except the body
consisting of all the systems mounted.
Basic purpose:- To connect all four wheels with a structure
which is rigid in bending and torsion.
It must be capable of supporting all components and
occupants and should absorb all kinds of loads fed into it
without deflecting unduly.
Can also be thought as Skelton on automobile or vehicle
without body.
Components of chassis
1. Frame
2. Suspension
3. Steering mechanism
4. Radiator
5. Engine/clutch/gear box
6. Propeller shaft
7. Differential
8. Braking system
9. Battery
10. Silencer
11. Fuel tank / fuel pipe
Types of chassis
 Back-bone chassis
 Ladder frame
 Tubular Space frame
 Monocoque
 ULSAB
(Ultralight steel auto body)
 Back bone chassis
Backbone chassis is very
simple: a strong tubular
backbone (usually in
rectangular section)
connects the front and rear
axle and provides nearly all
the mechanical strength.
Inside which there is space
for the drive shaft in case
of front-engine, rear-wheel
drive layout. The whole
drive train, engine and
suspensions are connected
to both ends of the
backbone
Advantages:- Strong enough for smaller sports cars.
Easy to make by hand thus cheap for low volume
production and more space saving
Disadvantages:- not strong enough for larger cars and
does not provide protection against side impact.
Who uses it:- LOTUS ESPIRIT / TVR / MARCOS
Ladder frame chassis:-
Its construction, indicated by its name, looks like a ladder -
two longitudinal rails interconnected by several lateral and
cross braces. The longitude members are the main stress
member. They deal with the load and also the longitudinal
forces caused by acceleration and braking. The lateral and
cross members provide resistance to lateral forces and
further increase torsion rigidity. 
Advantages:- Well, it has no much advantage in these days ...
it is easy and cheap for hand build, that's all. 
Disadvantages:- Since it is a 2 dimensional structure, torsion
rigidity is very much lower than other chassis, especially
when dealing with vertical load or bumps
Who uses it:- Most SUVs, classic cars, Lincoln Town Car,
Ford Crown Victoria
Tubular Space frame:-
Tubular space frame chassis employs dozens of circular-
section tubes (some may use square-section tubes for easier
connection to the body panels, though circular section
provides the maximum strength), position in different
directions to provide mechanical strength against forces
from anywhere. These tubes are welded together and forms a
very complex structure.
Advantages:-Very strong in any direction. (compare with
ladder chassis and monocoque chassis of the same weight)
Disadvantages:-Very complex, costly and time consuming
to be built. Impossible for robotized production. Besides, it
engages a lot of space, raise the door sill and result in difficult
access to the cabin. 
Who uses it:- All Ferrari
Before the 360M, Lamborghini
Diablo, Jaguar XJ220, Caterham.
Monocoque:-
Today, 99% cars produced in this planet are made of steel
monocoque chassis, thanks to its low production cost and
suitability to robotized production.
Monocoque is a one-piece structure which defines the overall
shape of the car. While ladder, tubular space frame and
backbone chassis provides only the stress members and need
to build the body around them,  monocoque chassis is
already incorporated with the body in a single piece
Monocoque chassis also benefit crash protection. Because it
uses a lot of metal, crumple zone can be built into the
structure.
Advantages:- Cheap for mass production. Inherently good
crash protection. Space efficient.
Disadvantages:- Heavy. Impossible for small-volume
production.
Who uses it:- Nearly all mass production cars, all current
Porsche.
ULSAB
Ultra Light Steel Auto Body
basically it has the same structure as a conventional
monocoque. What it differs from its donor is in minor details
- the use of "Hydroform" parts, sandwich steel and laser
beam welding.
Advantages:-Stronger and lighter then conventional
monocoque without increasing production cost

Disadvantages:-Still not strong or light enough for the best

sports cars.

Who uses it:-Opel Astra, BMW 3-series

Hydroforming:-
Hydroforming is a cost-effective way of shaping ductile 
metals such as aluminum,brass, low alloy steels, 
stainless steel into lightweight, structurally stiff and strong
pieces. One of the largest applications of hydroforming is the
automotive industry, which makes use of the complex shapes
possible by hydroforming to produce stronger, lighter, and
more rigid unibody structures for vehicles
Categorization of cars on basis of
position of “Pillars” & number of
boxes.
Sedan?

Saloon?

Hatch-back?

SUV?
Pillars:- anything that supports roof.
Types of pillars:-
1) Type “A” pillar:- Wind-Shield pillar
2) Type “B” pillar:- Pillar b/w two doors
3) Type “C” pillar:- Last side door/ support only one door
4) Type “D” pillar:- if there is any pillar after c pillar it is
called D pillar

• Boxes:- cannot cross over from one to second box.

S.U.V:- Ladder chassis , 2-boxes , A,B,C,D pillars.
Hatch-back:- 2 boxes , A,B,C, pillars
Sedan:- 3 boxes , A,B,C, pillars
Saloon :- same as Sedan just length is more than 4.5 m