Shri Vaishnav Vidyapeeth Vishwavidyalaya, Indore

Mechanical Engineering Department

BTAU 604

Vehicle Body Engineering

Laboratory Manual

Prepared by Asst. Prof. Sunil PipleyaMechanical Engineering Department

Shri Vaishnav Institute of Technology and Scinece, Indore

BTAU 604 (Vehicle Body Engineering) Laboratory Manual

Table of ContentsPractical

No.

Name of Practical Page

No.

Date Remarks

1Study of chassis frame & Location of its various

components with neat diagram.

2Study of typical car body construction and propose

new design sketches.

3

Study of Vehicle Structure analysis by simple

structural surface (SSS) method for saloon or simple

Van

4 Study of various types of commercial vehicle bodies.

5

Study driver’s seat position, passenger seat position,

its requirement and construction of typical truck/bus

body and propose new design sketches

6 Study of vehicle crash analysis.

7 Study of chassis and body alignment test.

Practical 1Aim: Study of chassis frame & Location of its various components with neat diagram.

Theory:

Introduction of Chassis Frame: 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

without 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.

Layout of Chassis and its main Components:

The following main components of the Chassis are

1. Frame: it is made up of long two members called side members riveted together with the

help of number of cross members.

2. Engine or Power plant: It provides the source of power

3. Clutch: It connects and disconnects the power from the engine fly wheel to the

transmission system.

4. Gear Box

5. U Joint

6. Propeller Shaft

7. Differential

FUNCTIONS OF THE CHASSIS FRAME:

1. To carry load of the passengers or goods carried in the body.

2. To support the load of the body, engine, gear box etc.

3. To withstand the forces caused due to the sudden braking or acceleration

4. To withstand the stresses caused due to the bad road condition.

5. To withstand centrifugal force while cornering

TYPES OF CHASSIS FRAMES:

There are three types of frames

1. Conventional frame

2. Integral frame

3. Semi-integral frame

1. Conventional frame: It has two long side members and 5 to 6 cross members joined

together with the help of rivets and bolts. The frame sections are used generally.

a. Channel Section - Good resistance to bending

b. Tabular Section - Good resistance to Torsion

c. Box Section - Good resistance to both bending and Torsion

2. Integral Frame: This frame is used now a days in most of the cars. There is no frame and

all the assembly units are attached to the body. All the functions of the frame carried out by

the body itself. Due to elimination of long frame it is cheaper and due to less weight most

economical also. Only disadvantage is repairing is difficult.

3. Semi - Integral Frame: In some vehicles half frame is fixed in the front end on which

engine gear box and front suspension is mounted. It has the advantage when the vehicle is

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

This type of frame is used in FIAT cars and some of the European and American cars.

VARIOUS LOADS ACTING ON THE FRAME:

Various loads acting on the frame are

1. Short duration Load - While crossing a broken patch.

2. Momentary duration Load - While taking a curve.

3. Impact Loads - Due to the collision of the vehicle.

4. Inertia Load - While applying brakes.

5. Static Loads - Loads due to chassis parts.

6. Over Loads - Beyond Design capacity.

STATE THE DIFFERENT BODIES USED IN AUTOMOBILES:

The Automobile bodies are divided in two groups

Body

Passenger Body & Commercial body

According to Chassis design the body can divided into

1. Conventional Type

2. Integral Type

3. Semi- Integral Type

According to other usage:

1. Light vehicle Bodies - cars, jeeps

2. Heavy vehicle Bodies Busses, Lorries�

3. Medium vehicle Bodies - Vans, Metadoors

REQUIREMENTS OF BODIES FOR VARIOUS TYPES OF VECHILE:

The body of the most vehicles should fulfill the following requirements:

1. The body should be light.

2. It should have minimum number of components.

3. It should provide sufficient space for passengers and luggage.

4. It should withstand vibrations while in motion.

5. It should offer minimum resistance to air.

6. It should be cheap and easy in manufacturing.

7. It should be attractive in shape and colour.

8. It should have uniformly distributed load.

9. It should have long fatigue life

10. It should provide good vision and ventilation.

Short Answer Questions:

1. List out the various components of chassis?

2. What are the functions of Chassis frame?

3. List out the types of Chassis frame?

4. What are the frame sections used in Automobiles?

5. What are the requirements of Bodies for various types of vehicles?

Essay Type Questions:

1. Draw the layout of conventional Chassis with a neat diagram and explain about various

parts on it?

2. What are the different classification of bodies used in Automobiles and explain?

Practical 2Aim: Study of typical car body construction and propose new design sketches.

Theory:

Cars can come in a large variety of different body styles. Some are still in production, while

others are of historical interest only. These styles are largely (though not completely)

independent of a car's classification in terms of price, size and intended broad market; the

same car model might be available in multiple body styles (or model ranges). For some of the

following terms, especially relating to four-wheel drive / SUV models and minivan / MPV

models, the distinction between body style and classification is particularly narrow.

In common usage such definitions are often blurred. Over time, the common usage of each

term evolves. For example, people often call 4-passenger sport coupés a "sports car", while

purists will insist that a sports car by definition is limited to two-place vehicles.

Body work:

In automotive engineering, the bodywork of an automobile is the structure which protects:

⦁ The occupants

⦁ Any other payload

⦁ The mechanical components.

In vehicles with a separate frame or chassis, the term bodywork is normally applied to only

the non-structural panels, including doors and other movable panels, but it may also be used

more generally to include the structural components which support the mechanical

components.

Body styles:

There are several common car body styles:

Enclosed: Micro Car⦁⦁ Sedan, known as a Saloon in British English

⦁ Hardtop

⦁ Coupé

⦁ 2+2

⦁ Notchback

⦁ Limousine

Open or partly enclosed:

⦁ Roadster

⦁ Convertible (or Cabriolet)

⦁ Stanhope body

⦁ Touring car

⦁ Town car

Rear door designs:

⦁ Station wagon or Estate car

⦁ Sedan delivery

⦁ Hearse

⦁ Hatchback

⦁ Liftback

Other:

⦁ Sport utility vehicle (SUV)

⦁ Crossover

⦁ Minivan

⦁ Coupe Utility

Micro car

Micro car designs boomed in post-World War II Europe, particularly in Germany.

Former military aircraft manufacturers such as Messerschmitt and Heinkel were prominent

micro car makers.

Aircraft designer Ernst Heinkel using aircraft principles and making it lighter yet faster with

a smaller engine.

Unique way to get in and out off the car.

Very small cars have also been popular in Japan and US.

It has a radical solution to the problem of parking.

PTV was the second-biggest-selling microcar in Spain.

A small car with very small engines being treated as motorcycles for tax and insurance

purposes.

No car drivers license was needed (Austria, Germany, Spain, Portugal).

Advantage in ease of parking .

Improves handling by reducing the angular inertia.

Modern Micro Cars:

The Smart (model Fortwo) launched in 1998 was a successful re-invention of the microcar.

The Corbin Sparrow, a singleseat electric microcar that can be licenced as a motorcycle.

The Global Electric Motorcars GEM, a 2- or 4-passenger "Golf Car" style vehicle.

The REVA electric vehicle from India.

Hatchbacks:

An automobile design, consisting of a passenger cabin with an integrated cargo space,

accessed from behind the vehicle by a tailgate. •

Opening rear tail gate. •

The interior design include folddown rear seats, which can be used as a cargo area. •

The rear seat can be folded partially (for instance 1/2, 1/3 or 2/3) or completely to expand the

cargo space.

Hot Hatchs:

High performance version of hatch back are knows as Hot hatchs •

The rear seat in line with the DPillar and the short space behind the rear wheels.

Sedan:

Type of car design consists of engine compartment, passenger compartment and a separate

boot •

A sedan posses fixed roof with fixed B pillar which seats four or more •

Most commonly it is a four-door; two-door models are rare.

Notchback sedan

A notchback sedan is a three-box sedan, where the passenger volume is very distinct from the

trunk volume of the vehicle. •

The roof is on one plane, generally parallel to the ground, the rear window (tail light) at a

sharp angle to the roof, and the trunk lid is also parallel to the ground.

Fastback sedan

A fastback sedan is a two-box sedan, with continuous slope from the roof to the base of the

decklid, but excludes the hatchback feature •

Typically this design is chosen for its aerodynamic advantages. Automakers can no longer

afford the penalty in fuel consumption produced by the traditional notchback three box form.

Two Door Sedan

The SAE defines such a vehicle as any two-door model with rear accommodation greater

than or equal to 33 cubic feet (0.934 m³) in volume (includes legroom, shoulder room, and

headroom)

Liftbacks

Liftbacks have either fastbacklike rear ends, which are significantly sloped compared to more

vertical hatchbacks, or are notchback-shaped •

For better aerodynamics • Based on Kamm back design trend.

COUPE:

Coupe was an enclosed two-seater mainly used in towns and was driven by a coachman. •

If the carriage had an emergency (tip-up) seat or a seat for a child, then it was a so called

three-quarter coupé •

Coupés generally, but not necessarily, have two doors, although automobile makers have

offered four-door coupés and three- and five-door hatchback coupés, as well. •

The SAE distinguishes a coupé from a sedan (saloon) primarily by interior volume •

SAE standard J1100 defines a coupé as a fixed-roof automobile with less than 33 ft2 of rear

interior Volume.

CONVERTIBLES:

Vehicles whose roofs may be showed or who side windows may be completely lowered.

In 1939 Plymouth introduced the first convertible with a power top •

It was activated by pneumatic cylinders, and removed a major inconvenience of open cars.

The trunk lid of the convertible should be altered from its parent production model •

Space for stowing the top, because the removal of the roof leads to a significant loss of

rigidity.

The only body item carried away from the parent sedan to the convertible model is the front

portion and a portion of the floor panel •

Need for high static and dynamic stiffness •

Dynamic stiffness determines the vehicle’s ride comfort •

Removing the roof of a sedan reduced the tensional stiffness to about one-six of its former

value.

Need for high static and dynamic stiffness •

Dynamic stiffness determines the vehicle’s ride comfort •

Removing the roof of a sedan reduced the tensional stiffness to about one-six of its former

value.

STATION WAGON / ESTATE:

Body style similar to a sedan but with an extended rear cargo area. •

Station wagons are based on sedan platform, having the main interior area extended to the

near-vertical rear window.

A hatchback car would not enjoy the full height of the passenger cabin all the way to the

back •

Rear glass of a hatchback being sloped further from vertical, and the hatch tending not to

reach fully to the rear bumper, as it commonly would in a station wagon. •

Station wagons also have side windows over the cargo area, whereas some hatchbacks have

thick C pillars and no cargo area windows.

“HYBRID” WAGON / SUV:

Wagons, however, are some of the most space-efficient vehicles available, generally offering

better fuel economy than sport-utility vehicles.

SUV:

An SUV is a passenger vehicle, which combines the towing capacity of a pickup truck with

the passenger-carrying space of a sedan. •

They have a powerful engine, have sufficient passenger space along with luggage

compartment behind the rear row seats and are designed for all terrains. •

They are non commercial vehicles with the BIW built on the chassis similar to a light truck

or a crew cab •

An offroader needs a long hood and an upright position. That lends the vehicle self-

assuredness and power.

PICKUP:

A pickup is a Light Motor Vehicle (LMV) with an open rear cargo area known as ‘bed'. They

are extremely popular in the USand feature factory-built integrated beds. The term also

applies to coupe-style utility vehicles that are based on a car chassis or a dedicated platform.

Such pickups are called ‘utes' in Australia and New Zealand. They are often available with

two or four doors for the passenger compartment and are called single-cab pickups or double-

cab pickups, respectively. An example of a pickup is the Isuzu D-Max V-Cross, which

features a double-cab design.

CROSSOVER:

A crossover is a vehicle built on a car platform but often with features such as SUV-like

increased ground clearance and a higher seating position. Crossovers are typically designed

only for light off-roading. An example of a crossover is the Ford Freestyle.

MPV:

MPVs (Multi-Purpose Vehicles) feature a one- or two-box design and are taller than station

wagons. They often see estate-like interior appointments and are generally regarded as

people-carriers, people-movers, minivans, or MUVs (Multi Utility Vehicles). MPVs are

designed to be spacious and usually get three rows of seating to accompany seven or more

passengers. An example of an MPV is the Toyota Innova Crysta.

Practical 3Aim: Study of Vehicle Structure analysis by simple structural surface (SSS) method for

saloon or simple Van.

Theory:

Structural analysis by Simple Structural Surfaces (SSS) method:

Many methods to determine loads and stresses

• Elementary method is beam method, FEM is advanced method and SSS is intermediate

• Developed by Pawlowski in 1964

• Determines loads in main structural elements

• Elements are assumed to be rigid in its plane

•Can carry loads in its plane – Tension, compression, shear and bending

• Loads normal to plane and bending out of plane is invalid and not allowed.

SSS method – Analysis of simple van (torsion case):

Ten structural components are considered

• If geometry is known and axle loads are known, edge loads (Q s) can be determined.

• For a fully laden van font axle load is lighter.

• By moment balance R’r can be determined.

The equilibrium of SSS‐2 and SSS‐ 3 are obtained by taking moments as Rf and R’r are

known.

P2 and P3 will be equal in magnitude as they act at the width of the vehicle and the torque at

the front and rear must be equal.

Considering SSS‐6• Q1 to Q5 will occur around periphery

• Applies opposite moment to P2 and P3

• Taking moment at A

P3(l1+l2+l3)−Q3(l1+l2+l3+l4)−Q4(h1−h2)−Q2h2−P2l1=0

• Consider SSS‐4 (front panel)

Q6h2−Q1w=0

• Consider SSS‐5 (rear door frame)

Q6h1−Q3w=0

Practical 4Aim: Study of various types of commercial vehicle bodies.

Theory:

COMMERCIAL VEHICLES

1. Flat platform2. Drop side3. Fixed sideFlat platform - A flat structure consists of a floor blade with edge members and  beams which are used to mount the engine and suspension elements.

Drop side - This type of body follows the main structure of the flat platform body with an addition of timber sides and a tailboard, capable of being drop to assist in loading and unloading.

Tipper body - The prime requirement of any tipping body is that it shall be a rigidunit capable of withstanding the rough usage to which the type of body is subjected.

Aluminium is used extensively for the construction of flat platform bodies for reasons of strength, durability and lightness.

Many of the less expensive light chassis have cheaper factory build timber or steel bodies. The aluminium body is used, to a greater extent, at the larger end of the range and on the more expensive type chassis. The floor is supported by cross bearer channels, the lipped channel or the J channel being used for most applications. Advantage of the J channel has is that floor fixing bolts are taken through the outstanding horizontal flange and the holes drilled to take the bolts through this flange do not weaken the channel in bending strength. Normal depth of a cross-bearer is 101.60mm 76.20mm depth may be used for light duty bodies.  Cross-bearer spacing is generally at about 558.8mm  In the case of brick lorries, cross-bearer  spacing should be restricted to 457.2mm A special rear bearer, incorporating a shroud plate is sometimes used. The shroud plate allows bracket attachment to the longitudinal and also provides protection for the end of the floor planks. Bearers are solid riveted or bolted to the longitudinal using angle brackets or special mounding brackets. The cross bearers are capped longitudinally by side rave section and are bolted or solid riveted to the bearers through top and bottom flanges.  

Two types of side rave are available,one with a chock rail and one without.  

The headboard is situated at the front of the body and behind the vehicle cab.  This is a structural member or assembly because it has to resist the load moving forward and crushing the cab when the vehicle brakes are applied.

The bulkhead pillars are bolted to the longitudinal and the side or corner pillars firmly attached to the side rave using gussets. The head board may be 10swg sheet, but generally heavy-duty corrugated plank section is used to provide strength.

                                                                        

Fixed bodies are made of the side which is fixed in side pillars and can be opened  only from rear tail gate for unloading and loading.

Drop side bodies:

A drop side body is a flat platform with hinged sides and tailboard, held in the upright position by fastening to short vertical pillars that are generally removable. The sides are normally made up by interlocking hollow plank sections . 

TIPPER BODY:

A tipper body is attached to a rigid cab chassis and is used to carry a wide range of bulk products, such as gravel, sand and grain. It is hinged at the rear which allows the front of the truck bed to be raised and the contents set down behind / side the truck.CLASSIFICATION:

Based on type of tipping method    • Hydraulic    • ElectricBased on location of tipping mechanism    • Front end tipping    • Under body tippingBased on direction of unloading   • Single way   • Three way

Tanker body: 

Commodities carried by tanker includes fuel, oils, milk, water, varnish and edible oils etc. In the case of fuel transport, to ensure safe handling, internal baffle plates are used to cut down the surge of liquid.

USES OF TANKER BODY:  Used to transport goods like,detergent,varnish,edible oil,resins,fat,sugar in solution,liquid gaseous,fuel, oil, milk and water in bulk.

CLASSIFICATION OF TANKER BODY:1.According to the type of liquid carrying:a. water tank body

b. Fuel tank bodyc. Chemical liquids tank body

2.According to the shape of the tanker body:a. Circular (round) cross sectionb. Elliptical cross section 3.According to bulkheads:

a. Baffled tanksb. Un baffled tanks (smooth bore tanks)

WATER TANK BODY:

It is mainly composed of the truck chassis, water inlet,outlet system and the water tank body. It is a cylindrical, horizontal tank mounted onto the truck chassis A water tank truck is mostly used for storing water and transporting the same to some places where there is an urgent need for water. A sprinkler water tank truck is used for making the city environment clean and beautiful by cleaning and watering the streets, plants, and grass. Water tank trucks have different volume capacity. The rear sprinkler, and side spraying of a water tank body are made possible with the tank's fire hose coupling, working platform, and self-discharge valve. A rotatable water cannon is installed on the working platform to create various spraying functions and adjustments to create mist, drizzle, moderate rain, or heavy rain depending on the different purposes and environment. It is made of various materials such as stainless steel,carbon steel, aluminum, and fiberglass-reinforced plastic. The rigid steel body is further sprayed with superior quality special paint to allow it to be more solid and safe.

FUEL TANKS:  

FUEL TANK TruckIt is constructed in such a way to safely carry different kinds of fuel to and from its destination. Some fuel tank body are used to transport different grades of fuel to and from the gasoline station can be              - insulated or non-insulated,              - pressurized or non-pressurized,              - single or multiple compartments. Some of the materials used to build these fuel tanks include aluminum, fiberglass reinforced plastic or FRP, stainless steel, and carbon steel. Insulated tank is used to Minimize fuel temperature increases inside the tank, reducing fuel loss due to evaporation. The fuel tank body that carries these flammable gases is often pressurized and can carry around 1,000 to 3,000 gallons of this fuel at one time. Some fuel tanks can be compartmentalized to carry 2, 3,4, or 5 different kinds of fuel at one time in one cylindrical containment unit. 

CHEMICAL LIQUIDS TANK BODY:

chemical liquid tank truck is designed to carry corrosive, hazardous chemical liquids . It is mainly composed of a chassis, tank body,discharge system, as well as some protective devices. The tank can be constructed of carbon steel,stainless steel, aluminum alloy, or other materials,according to the specific properties of the transporting medium. Some tank trucks can carry a variety of products at once due to their internal divisions in their tank,allowing for an increased number of delivery options

 CIRCULAR CROSS SECTION:

circular cross section is readily adaptable to frame less construction. when a circular tank is inclined towards the rear the center of gravity can be equal to that of an elliptical tank.

ELLIPTICAL SECTION:

 

Used for a wide range of purposes, Elliptical tanks are a popular form for tanks that hold large volumes of liquids. Low Center of Gravity• Capacity– A tank made in an elliptical shape provides a low center of gravity when it is placed on itsside.– For holding large loads of liquids, that distribution of a  tank's contents is particularly effective at providing stability.– The low center of gravity also allows tanks located on truck trailers to sit lower to the ground, providing better sight lines for truck drivers.– An elliptical tank has significantly greater capacity than a round tank with the same diameter

BULKHEADS:  Some large tanks are divided into several smaller tanks by bulkheads. Bulkheads are liquid-tight separators between compartments inside the tank   

BAFFLED TANKS:

Elliptical tank

   Some tanks have compartments in them that have holes. If the compartment walls have holes in them, they are called baffles. Baffles let the liquid flow through and help control the forward and backward liquid surge when the vehicle is traveling, especially at higher speeds. However, side to side surge can still occur which can cause a rollover. It is used in fuel transporters to ensure safe handlingUN-BAFFLED TANKS:

Also known as Smooth bore tanks. They have nothing inside to slow down the flow of the liquid. Therefore, forward and back surge is very strong. Smooth bore tanks are usually transport food products,Sanitation,Corrosive liquids.DESIGN CONSIDERATIONS: The security of the discharge hoses  Provide ample drain holes to enable the liquid to drain away rather than to remain inside the containerSelection of material for the right tanka. When corrosive liquids are to be carried, the material must resist their corrosive action and stainless steel be usedb. To provide a none reactive surface to the load and for cleanness', metals such as zinc aluminum cadmium and copper  Aluminum has long been used for fabricating tankers to carry liquids such as petrol and fuel oils. largely on account of its weight/strength relationship which makes possible an uplift of between 5% and 8% carrying capacity when compared with a similar construction in steel

Light Commercial vehicle types:  The light ,four wheeled rigid commercial vehicle with an unladen weight  of less than 3.05tonnes.The cab which on   Panel vans  Production van          1.Standard van          2.Chassis cab                 i)Tipper and drop sides                 ii)Box van                iii)Luton head vans          3.Chassis dash

 Panel vans:

  

GVW up to 3.5 tones. Tradesman for door to door and high street delivery. Lighter modes are based on the standard motor car underbody arrangement. Bodies are steel pressings with large doors to facilitate entry, exit and access for loading and unloading by one or two doors at the rear. Almost all are the unitary or integral construction.Standard van:

The standard van arrangement is used for general local delivery work and, after body shell conversions and interior fitting out, for ambulance, motor caravans and security vans.Chassis cab:

  The chassis arrangement comes in three different versions, i. tipper and drop sides (A) ii. Box van (B) Iii. Luton head van (C)

Chassis dash:

   Chassis dash arrangement is used extensively for integral body/cab “walk-through” type vans. 

Dimensions of driver’s seat:

The following points must have in mind when planning the driver’s seating position1. The most comfortable position of the body is achieved when the bulk of the weight of the seated person is taken by the ischial bones.2. The seat cushions should be fairly rigid and must have sufficient shock absorbingqualities to prevent resonance of any springs that may be incorporated.3. A good back-rest relieves the neck and shoulder muscles.4. The angle between the seat and back-rest must be obtuse.5. Armrests reduce tiredness.

Drivers cab design:

1. Forward control cab2. Normal control cab3. long distance cab

The design of the cab should ensure a degree of comfort for the group directlyrelated to the duration of the work inside it, modern cabs in trucks are havingcomfortable as passenger cars.

Normal control:

 In Normal control vehicle, engine is located in front of the driver’s cab to give more cab space, less noise, heat and ease entry and exit.Forward control:

In forward control vehicle, engine is located either at the side or below the driver’s cab This type has its cab built over the engine and has the advantage of additional length available for the payload and a better angle of vision. Its disadvantages include less cab space for crew and engine maintenance can be more difficult unless specialized equipment is available or the cab is designed to tilt forward. A variation to forward control aimed at giving ease of entry and exit for door to door delivery work and more space for the crew is the semi forward control type.