G.VIJAY BHASKAR

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Vehicle Body Engineering

• G.VIJAY BHASKAR
• ASST.PROF
• AUTOMOBILE ENGININEERING DEPT

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UNIT I
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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

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Our Industry is Under Siege
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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
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The Motor Vehicle Safety Equipment Exists Now to
Help Reduce Crashes and Rollovers Its Called
Electronic Stability Control
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Technology is our passion but safety is our
business
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Electronic Stability Control Improves Safety
We Have Safety Technology Today to Make Mobility
Safer!
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The Bottom Line
Make the chassis itselfelectronically
intelligent
Raise comfort and safety to new levels without
sacrifices
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Passive Safety is Job Three

• The next frontier isto prevent the crash from
  occurring in the first place

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Active Safety is Job One

• The key isto prevent the crash from occurring
  in the first place

This is active safety
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Opportunities in Smart Safety Systems

• The key isto prevent the crash from occurring
  in the first place

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UNIT II
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Automotive Safety Continuum
Phase 1 Avoid problem situations.
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Automotive Safety Continuum
Phase 1 Avoid problem situations.
Phase 2 Maintain control if
trouble begins
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Automotive Safety Continuum
Phase 1 Avoid problem situations.
Phase 2 Maintain control if
trouble begins
Phase 3 Protection when the
crash is unavoidable
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Automotive Safety Continuum
Phase 1 Avoid problem situations.
Phase 2 Maintain control if
trouble begins
Our Focus Should be Crash Avoidance
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Improved Safety Through Functional Integration
Electronics
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Networking Active and Passive Technologies Will
Improve Safety
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Networking Active and Passive Technologies Will
Improve Safety
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Continental Brings together Know-How in Tires,
Electronics and Brake and Chassis
Electronics
Tires
Brake Chassis
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Full Circle

• Beforethe industry needs to do moreon the
  safety front

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Full Circle

• Beforethe industry needs to do moreon the
  safety front
• Now we need to do more to make our technology
  better understood and sought after in the new
  vehicle marketplace

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Our Challenge Make Consumers More Aware of
Active Vehicle Safety

• Develop public awarenessof these possibilities
  to engineer a miss

Get them to buy them!
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• J.D. Power Associates Survey Ranked Stability
  Control among Top 10 Desired Features

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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

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• Bottom Line in the Mercedes Study

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

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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

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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

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Raising Consumer Awareness
www.esceducation.org
www.drivesaferamerica.org
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Are We Ready?

• The Technology to Help Drivers Avoid Crashes
  Altogether and Make all Vehicles Safer is Within
  Our Grasp

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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

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UNIT III
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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.
  

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AERODYNAMIC FORCES ON A BODY

• LIFT
• (DOWNFORCE)
• DRAG
• WEIGHT
• THRUST

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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.

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WHY WE NEED TO IMPROVE AERODYNAMICS IN CARS

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

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Aerodynamics to make the efficient even more
efficient!
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Mythbusters Tailgait down or up?
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Mythbusters Tailgait down or up?
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AERODYNAMICS IN MCLAREN F1

• SPECIFICATIONS
• FRONT END
• REAR END
• SCOOPS
• WINGS

Mclaren F1
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AERODYNAMIC DEVICES

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

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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.

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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

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CONCLUSION

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

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UNIT IV
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Back
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Back
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Back
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FRONT END

• FRONTAL PRESSURE
• PRESSURE DIFFERENCE
• MINIMISE FRONTAL AREA
• REDUCE cd

Back
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SCOOPS

• ENGINE COOLING
• INCREASESFLOW RATE OF AIR
• 
  

Back
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REAR END

• REAR VACUM
• FLOW DETACHEMENT
• TURBULANCE

Back
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WINGS

• PRODUCE DOWNFORCE
• REDUCE DRAG

Back
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Back
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Back
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COEFFICIENT OF DRAG

• Drag 1/2xd x Cd x A Xv2
• Measure of aerodynamic
• efficiency.

Back
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SPECIFICATIONS

• EngineTypeV12
• Curb Weight 1100 kg.
• Displacement6064 cc
• Horsepower627 bhp _at_ 7400 rpm
• Torque479 lb-ft _at_ 4000 rpm
• Performance0-60 mph3.2 sec
• 0-100 mph6.3 sec
• Top Speed240 mph /hr

BACK
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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 Courtesy Car Body Design http//www.c
arbodydesign.com/articles/2005-04-13-chassis-histo
ry/2005-04-13-chassis-history.php
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Moving Forward...
Honda Civic Frame http//automobiles.honda.com/ima
ges/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.

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A Quick Comparison
Typical Ladder Frame
Monocoques
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What its all About

• Today, the new revolution in 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.

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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 http//www.efunda.com/materia
ls/alloys/carbon_steels/show_carbon.cfm?IDAISI_10
20propallPage_TitleAISI201020 http//www.efun
da.com/materials/alloys/aluminum/show_aluminum.cfm
?IDAA_5182show_propallPage_TitleAA205182
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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.

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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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An Increasing Trend
http//www2.prnewswire.com/mnr/duckerworldwide/375
15/
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Cars Utilizing Al Frames

• Audi A8
• Jaguar XJ
• Corvette Z06
• Honda NSX
• Audi A2
• Audi R8

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Weight

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

Cars with Mostly Al Space Frames
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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.

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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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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.

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UNIT V
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In The Future
http//andrewbeard.wordpress.com/2009/05/11/techno
logy-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 Carrera GT http//upload.wikimedia.org/wik
ipedia/commons/thumb/6/65/Porsche_Carrera_GT_-_Goo
dwood_Breakfast_Club_28July_200829.jpg/800px-Por
sche_Carrera_GT_-_Goodwood_Breakfast_Club_28July_
200829.jpg
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References

• Building an aluminum carhttp//www.allbusiness.co
  m/professional-scientific/scientific-research-deve
  lopment/443897-1.html
• History of Automobile Body and Chassishttp//www.
  carbodydesign.com/articles/2005-04-13-chassis-hist
  ory/2005-04-13-chassis-history.php
• Automobile Bodies Can Aluminum Be an Economical
  Alternative to Steel?http//www.tms.org/pubs/jour
  nals/JOM/0108/Kelkar-0108.html
• Different Types of Chassishttp//www.autozine.org
  /technical_school/chassis/tech_chassis2.htm
• Aluminum Versus Steelhttp//www.travistrailer.com
  /public/pag16.aspx